FMEA-MSR

E1NS FMEA-MSR

Method and practice guide

Failure mode and effects analysis (FMEA) is a method for detecting and preventing further errors. A company that manufactures products benefits from an analysis process that detects and eliminates invisible defects on time.

MSR is an improved analysis method for fault detection and error prevention. MSR stands for monitoring and system reaction. Monitoring stands for more intensive monitoring of a production development process. Improved monitoring means that the person in charge can react better to system errors or disruptions in the production process.

The FMEA-MSR form has been part of the new FMEA volume from AIAG and VDA since 2019. It differs visually from the normal FMEA form and there are also various differences in the methodology. Help completing this FMEA form can be provided by detailed new FMEA training.

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How is the FMEA-MSR form used?

How can high risks be reduced in your FMEA and the original consequences of errors be avoided through reliable monitoring? Our video shows you how this form can be advantageously implemented in e1ns.

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Application of FMEA analysis

The new FMEA analysis is used when errors cannot be further reduced with the classic analysis. This is the case, for example, when individual components have a high probability of failure during a production development process. The classic FMEA is not able to recognize these errors and evaluate them accordingly.

The result can be associated with additional costs for a company because unrecognized risks can contribute to the disruption - in the worst case, the shutdown - of a production process. Such faults can still be identified and eliminated by an improved analysis method: FMEA-MSR.

This method results in more intensive monitoring of the production development process. As a result, the original error sequence (indicator is a high B value) is replaced by a low error sequence (indicator is a low B value).

Example

Practical instructions - Airbag example

The new FMEA analysis method is presented using a practical example. The initial situation is that the airbag in a vehicle opens uncontrollably due to one or more errors while driving.

Analysis with classic FMEA

Software screen of a analysis with a classic FMEA

The problem can be handled easily and simply with the help of various modules in e1ns (e1ns.architect and e1ns.methods). The FMEA software includes different levels on which different forms can be filled out. Participants in an FMEA training are intensively familiarized with the new functions. The functional safety of the airbag is first checked using an FMEA form (functional analysis). The error analysis follows in a second step. Lastly, risk analysis helps ensure that the error does not repeat itself once the cause has been identified.

After running the classic FMEA analysis process, further errors arise which means that the problem of the airbag opening while driving could not be finally solved. The new version of the FMEA analysis ensures that errors that were not taken into account in the classic analysis process are identified and avoided. The switch from classic FMEA to FMEA-MSR can be done with the simple push of a button.

Analysis with FMEA-MSR

The focus of the FMEA-MSR is on the airbag control system. The errors defined here could not be further identified or eliminated with the original version of the FMEA analysis method. Strong monitoring takes place as part of the analysis process with MSR. After this has happened, the person responsible for monitoring can trigger an appropriate reaction.

During further analysis, the FMEA software solution performs an important task by itemizing each error that causes the airbag to not function properly. If the person responsible for controlling the process determines that this error was the cause of the airbag deploying uncontrollably, he or she can now take the appropriate steps.

This step of FMEA analysis must also be analyzed in the FMEA form. It is also shown here that an error is linked to a function. Here, the person responsible for the FMEA analysis receives the information that the function of the airbag is blocked due to a specific error. The classic FMEA can only link functions with functions.

With FMEA-MSR it is possible to switch the high error sequence in the production of the airbag to a low error sequence. Instead of an error sequence of ten, after the analysis, there is only an error sequence of, for example, six.

In this way, the FMEA software helps ensure that the error does not repeat itself in future airbag production. This must also be documented in an FMEA form. As a solution, FMEA-MSR provides data for a deactivating airbag system.

FMEA form after analysis with MSR

In the e1ns.architect module you can change the view using a button. In the new overview is possible to link functions with errors.

To block an error sequence, you can use a selection field to choose between 'Monitoring' and 'Response' to monitor a specific function or define it as a reaction to a function. For this to happen smoothly, you need another error sequence, which is rated lower and follows when the error sequence to be blocked is correctly prevented.

The new FMEA-MSR form, like the classic form, lists the functional analysis and the error analysis. In addition, the results of the FMEA-MSR are documented in a supplementary column. The presentation takes place in further sub-columns, which are presented in more detail in the FMEA manual.

The information about monitoring and system response must be automatically taken over by the FMEA software. The user now has the task of evaluating the results of the analysis accordingly. In addition to monitoring and the reaction of the system, the user is also informed about the effectiveness of the change to a lower error rate.

Your benefits

Advantages of FMEA software

FMEA-MSR is an improved version of the classic analysis for error detection and error prevention.
The FMEA software e1ns allows the user to integrate additional monitoring methods into the entire FMEA analysis process.
The software helps ensure that errors in every production process can be identified and eliminated on time. It is therefore suitable for reducing the costs of a production process in the long term.
Users can apply the knowledge from FMEA training directly in the new version of FMEA analysis and thereby contribute to cost savings in their company.

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