Failure Mode & Effects Analysis (FMEA)

Situation

Our client (a fresh food manufacturer of ‘own brand’ chilled desserts) was undergoing a site rationalisation programme. This involved moving several production lines from one site to another and re-configuring and refurbishing the equipment as part of the process. They recognised that a FMEA would help them identify any potential causes and effects of failure in the production lines. Armed with this information they would then be able to take steps to minimise the impact of any potential failures on the planned timescales to commission the lines

Our solution We devised a three-stage plan of attack:

- Process Map the entire production line
- Carry out the FMEA process including scoring and prioritising the various issues
- Identifying the responsibilities and actions to be take

As a result, a number of potential problems were identified and resolved prior to commissioning. When the line was installed, the company was able to achieve product throughput in line with their project plan.

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