We are currently working on implementing an FMEA template for our existing systems using Dyadem's FMEA Pro, and it has been quite challenging. Our systems have been in operation for approximately 9 years, with spares being added over time based on real-time failure experiences. Job plans and PMs have also been continuously enhanced. We have a robust NC/CAPA system in place for root cause failure analysis and implementing corrective actions. However, we are facing two main challenges. Firstly, FMEA Pro does not easily integrate existing system information for analyzing spares, PMs, and job plans. We are working on determining the best approach for conducting the FMEA and organizing the layout in a logical manner. It feels redundant to start from scratch when we already have a wealth of data on existing spares. Listing functions and failure modes for each spare has proven to be time-consuming and somewhat redundant. Secondly, we believe that our current real-time improvement programs, combined with our experienced workforce, may already cover what the FMEA is meant to validate. Our existing improvement processes are efficient at maintaining equipment across all systems in real-time. An inexperienced FMEA team may not be able to identify the actual failure experiences we have encountered, potentially leading to ineffective results. If anyone has an example of an FMEA that successfully incorporates existing systems, including equipment, spares, PMs, job plans, and CM data, we would greatly appreciate the opportunity to review it for inspiration. Thank you, J.
Wally, if FMEA-Pro has Open Data Base Configuration and your current data is in ODBC format, you can create a data transformer to transfer data seamlessly. This can be especially helpful for filling in any missing data fields. Most RCM packages use ODBC, so if FMEA-Pro does not, it may be worth considering using an RCM package instead. Performing an FMEA solely to validate current practices may not be the best approach from a business standpoint. If your failure and downtime trends are showing improvement, it is a strong indicator that you are likely on the right track.
Thank you for your response, Vee. I wanted to clarify my issue with FMEA-Pro. It is an open database, and although our servers are validated, FMEA-Pro itself has not been validated. Therefore, we do not allow direct communication between the two databases. Instead, we use a database query program called Brio to extract data from Maximo. The results are then exported to Excel and subsequently imported into FMEA-Pro. While this process is not overly complex, I am struggling with how to design the template effectively. Initially, we listed the equipment with its corresponding spares underneath. While this seemed logical, we ended up listing failure modes for each spare instead of the equipment itself. I am unsure if a Bill of Material (BOM) or Build List should be incorporated into an FMEA. I would greatly benefit from seeing a well-structured FMEA on an existing system to understand which data is crucial for consideration during the analysis and which data is for reference or comparison with the FMEA results. I am debating whether to start from scratch or utilize existing information such as CMs (Configuration Management), PMs (Preventive Maintenance), job plans, and spares. Any guidance on this matter would be appreciated. Thank you, J-
Wally, you inquired about whether a Bill of Material (BOM) or Build List should be included in an FMEA. As far as I know, a BOM is typically a result of tasks generated from an FMEA. While every failure mode (FM) may have several related parts, not every component in a BOM necessarily corresponds to a specific FM, as multiple parts may be related to the same FM. It would be beneficial to observe a well-executed FMEA within an existing system to understand which data is essential for the FMEA process and which data is used for reference or comparison to the FMEA output. Functional FMEAs, such as those used in Reliability Centered Maintenance (RCM), are the most effective in determining maintenance tasks. On the other hand, Design FMEAs involve analyzing every component part in a BOM, making them less ideal for maintenance task identification due to their detailed nature and high costs. When deciding whether to start fresh or utilize existing information such as CMs, PMs, job plans, and spare parts, I believe it is beneficial to consider existing data. Kindly refer to the email I previously sent for further details.
Hi J, I can understand your predicament about trying to migrate existing experiential data into the FMEA Pro environment. In terms of integration, you might want to consider using middleware software or an API, if Dyadem offers one, to map your existing data to the FMEA format. As for the redundancy you're experiencing - a possible workaround could be to group your spares by function or by system and then perform a generic FMEA for each group. That way, FMEA might complement your existing process instead of feeling like a duplicate effort. Lastly, it's true that an inexperienced FMEA team might not recognize all nuances, but remember, the goal of FMEA is not just to validate but also to predict and prevent possible future failures. For that perspective, the involvement of a fresh team might be beneficial. Hope this helps.
Your situation indeed sounds challenging, especially when there's a wealth of pre-existing data that you need to integrate into a new system, like FMEA Pro. One thing you might consider is finding a data specialist who could help you integrate your existing information into the new tools. Additionally, while it might seem as though your current improvement programs cover all bases, don't underestimate the value that FMEA can bring in terms of finding potential flaws or inefficiencies that might otherwise go unnoticed. Remember that the FMEA is not just about validating your current processes; it's also about proactively identifying areas for improvement. It's great that you have a robust CAPA already, but FMEA could potentially enhance it by adding another layer of predictive analysis. As for examples, I'm afraid I can't share directly due to confidentiality restrictions, but I'd recommend looking into best practice guidelines and case studies from highly regulated industries, as they often have robust FMEA procedures. Keep pushing through, J! The process might be difficult now, but the potential benefits on the horizon are huge.
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: Answer: The challenges include difficulties in integrating existing system information into the FMEA tool for analyzing spares, PMs, and job plans, as well as concerns about redundancy and time-consuming processes in listing functions and failure modes for each spare.
Answer: Answer: The existing real-time improvement programs and experienced workforce may cover what the FMEA is meant to validate, potentially leading to concerns about the effectiveness of the FMEA process in identifying actual failure experiences.
Answer: Answer: While challenging, successful examples of incorporating existing systems into an FMEA template exist, and reviewing such examples for inspiration can provide insights on how to structure the FMEA layout in a logical manner.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.