E1NS R-FMEA

Improve the quality of your FMEA

In order to confront FMEA results with real situations, the Reverse FMEA method was introduced. It no longer deals only with imagined causes of defects, but is carried out directly on site at the respective process or activity step.

Method for Verifying the Process FMEA

This method can be seen as an addition to the content of a Process FMEA, but from a different perspective. In order to bring together different perspectives, usually an interdisciplinary FMEA team including FMEA moderator is used. The proximity to the process or the individual activity step allows a comparison between the documented results of the Process FMEA and the actual production processes.

What is the goal of Reverse-FMEA?

Image explanation for reverse FMEA

FMEA is considered one of the most powerful risk prevention tools. However, it is performed by multidisciplinary teams in meeting rooms brainstorming away from the reality of the field and real manufacturing situations.

The purpose of Reverse-FMEA is to validate the assumptions made when the FMEA was created and see if they still hold true. In this process, the observations from the Reverse-FMEA are incorporated into the existing Process FMEA and further processed there. This means that new defects and new causes of defects may be discovered, which may also lead to a re-evaluation of significance, avoidance and detection measures. This serves primarily to keep the Process FMEA up to date and to document an image of the actual situation. Necessary actions are also to be implemented.

How Reverse-FMEA validates the performance of your manufacturing processes

To date, there is no mandatory normative requirement or binding rules from any industry association for the implementation of a Reverse FMEA. However, many OEMs (BMW Group, Daimler AG, Ford Motor Company, Geely Group, General Motors, VW Group, etc.) now require their suppliers to perform R-FMEA. As a result, and due to the proven effectiveness of this method, companies have started to adopt R-FMEA into their existing processes and are developing their own approaches and rules.

There is no specific approach for implementation, but in general most companies define their own methodology in their FMEA standards. Following an R-FMEA checklist is recommended.

However, some approaches are also listed in customer-specific requirements, for example in Ford's CSR agreements.

E1NS R-FMEA

Successfully implementing the Reverse-FMEA

  • Milestones and tasks are planned for the R-FMEA process and responsible persons are appointed.
  • PFMEA and visual process flow chart are checked by the team, e.g. in a review.
  • Process steps that are to be examined in production are prioritized/marked.
  • Findings from practical application in production are logged and the log refers directly to FMEA content.
  • The PFMEA is updated and versioned. The audit trail documents the changes.
  • All comments and documents of the R-FMEA process refer directly to the PFMEA and the process flow chart.
  • The identification and decision on special features in the R-FMEA process are directly linked to the feature observation process integrated in e1ns.
  • The e1ns Lessons Learned process updates the family/baseline FMEA data from the R-FMEA (e.g. revised controls, OD numbers, new recommended actions).
  • R-FMEA activity reports can be created using the evaluation tool integrated in e1ns.

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Meeting FORD's CSR. Prepare for the Future.

This video is ideal for Ford suppliers seeking clarity on the new standard or those looking for strategies to improve their quality risk management processes.

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FMEA

Creation of FMEAs: Worldwide, easily and in a team.

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Inspection Plan

Quality assurance measurements during production.

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Process Flow

Process flows for identifying the causes of possible malfunctions.

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DRBFM

Change management with DRBFM: Success with methods.

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Functional safety (ISO 26262) and FMEDA.

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Permanent complaints resolution.

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Ensure consistency of special characteristics.

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