Why FMEA and FTA go hand in hand - and how companies benefit from this

FMEA and FTA are standard tools in the risk management of technical systems. Both methods are well-established, proven, and widely used in many companies. And yet there is a key problem: they are often applied separately from one another.

What may seem inconsequential at first glance often has far-reaching consequences in practice - for quality, efficiency, and ultimately for product safety.

Two methods, two perspectives

To understand why the combination of FMEA and FTA is so effective, it is worth taking a closer look at their roles in risk management.

FMEA (Failure Mode and Effects Analysis)

• begins at the system or functional level,
• identifies potential defects across functions and requirements, and
• aims to identify risks early on and address them proactively at the most detailed level possible.

FTA (Fault Tree Analysis)

• starts with an undesirable top-level event (e.g., a system failure),
• systematically analyzes which combinations of causes lead to this event, and
• highlights systemic relationships and dependencies.

Both methods are therefore top-down in their approach, but they have different focuses:

• FMEA focuses on preventive measures and a high level of detail.
• FTA focuses on systemic causal chains and interrelationships.

The real problem: worlds apart

In many companies, the reality is this:

• FMEA is developed by the quality or development team.
• FTA is developed in the context of systems engineering and reliability.
• The two analyses are rarely linked.

This results in:

• information being modeled twice,
• assumptions diverging, and
• important relationships remaining hidden.

The result: a fragmented view of risk.

Why this is riskier than it seems

At first glance, both methods seem to work even when used separately. But upon closer inspection, critical gaps become apparent:

• The causes of errors are identified but not placed within the context of the system.
• System failures are analyzed—without clear traceability to specific causes.
• Decisions are based on incomplete information.

In short: The system is never understood as a whole.

What changes as a result of the combination

When FMEA and FTA are combined, a much clearer picture emerges:

Causes and effects are linked

• Defects identified in the FMEA are incorporated into the FTA.
• System failures can be traced back to specific causes.

Risks become fully traceable.

Decisions become more informed

• Consistent data foundation
• Clear prioritization of risks

Less gut feeling, more solid foundation.

The effort required decreases

• No duplicate modeling
• Less need for coordination

Efficiency gains in day-to-day operations.

Cooperation is improving

Teams no longer work in silos, but rather follow a shared model. In practice, this is often the most effective approach.

Particularly relevant in complex industries

The combination of FMEA and FTA is becoming increasingly important - especially in areas where systems are complex and safety-critical:

• Automotive – due to increasing system integration and functional safety
• Medical Devices – Due to stringent regulatory requirements
• Aerospace & Defense – due to extreme safety requirements and standards
• Electronics – due to complex interactions and rapid development cycles

In all these areas, it is no longer sufficient to consider risks in isolation.

Conclusion: Silos are the real risk

FMEA and FTA are not competing methods - they complement each other perfectly.

And yet, using them separately poses one of the greatest risks in modern product development.

• Separately: a fragmented view of risks
• Together: a holistic understanding and better decisions

By using FMEA and FTA together in an integrated approach, key benefits can be realized:

• Consistent data foundation: Root causes, probabilities, and assessments are applied uniformly
• Greater efficiency: Shared data, templates, and models reduce redundant work
• Improved collaboration: Teams work based on a shared understanding rather than in isolated silos
• End-to-end traceability: The relationships between root causes and system failures become transparent and traceable

It is precisely this integration that is the key to modern, scalable risk management.

How closely are FMEA and FTA linked in your company today? Do you have a comprehensive understanding of your risks - from cause to effect? If not, this is where there is enormous potential - for better decisions, more efficient processes, and greater product safety.