Two common methodologies for manufacturing analytics are Failure Mode and Effects Analysis (FMEA) and Failure Mode, Effects, and Criticality Analysis (FMECA).
If the terms look (very) similar, that’s by design; FMECA builds on FMEA by adding quantitative criticality analysis to evaluate the likelihood and impact of failures. The two approaches differ in depth, data requirements and how risk is quantified.
Here’s what you need to know about FMEA, FMECA and choosing the right method for your business.
What is FMEA (failure mode and effects analysis)?
FMEA is a systematic approach to identifying potential failure modes. A failure mode describes how a component or system fails. It defines the specific way a failure occurs, not the sequence of events leading to it.
Consider an industrial packaging machine that suddenly loses connection to its control valves. The loss of connection is the observed effect, but without identifying the failure mode efforts made to solve the issue could result in fixing symptoms rather than finding the root cause of failure.
FMEA breaks failure analysis into three components:
- Failure mode
- Effects of failure
- Causes of failure
Analysis of these components helps companies identify three metrics: The potential severity of an issue (S), the likelihood of a failure occurring (O) and the likelihood that the issue will not be detected (D). Each metric is scored, typically on a scale of 1-10. Then, they are multiplied together to yield what’s known as the risk priority number (RPN). Higher RPN values indicate higher risk and help prioritize corrective actions.
Here’s an example. A critical piece of production equipment has a severity rating of 9, since if it goes down, the result is a significant bottleneck. Because it is well-maintained, it has an occurrence likelihood of 3 and a failed detection rate of 5.
This gives:
RPN = S x O x D = 9 x 3 x 5 = 135.
Common types of FMEA include process FMEA, design FMEA and system FMEA. Its primary goal is to help prioritize corrective actions by creating a consistent and centralized scale. In addition, FMEA supports both predictive and preventive maintenance programs.
What is FMECA (failure mode, effects and criticality analysis)?
FMECA expands on FMEA with the addition of criticality analysis.
FMECA uses quantitative criticality analysis to assess failure impact using three inputs:
- Failure rate data
- Probability of occurrence
- Mission impact
FMECA differs from FMEA by incorporating mission impact into a quantitative criticality score. While failure rate and occurrence data are used in FMEA, FMECA adds mission impact. Mission impact is defined based on operational priorities but is incorporated into a structured criticality calculation.
Criticality is typically quantified using methods such as fault tree analysis and bowtie analysis, while digital twins can support these efforts by providing real-time system modeling and data for more informed evaluation.
For example, if the mission of a manufacturing company is to improve production throughput, any failures that impact this goal will be assigned a higher mission impact score, meaning maintenance and reliability processes will target machines that are responsible for high-volume production or act as bottlenecks for other processes.
If the company’s goal is product quality rather than quantity, criticality analysis adjusts to reflect this priority. Operations such as manual and automated quality control take center stage over pure production output.
FMECA is often used in:
- Aerospace manufacturing
- Defense contracting
- Energy production
- High-risk industrial operations
Using FMECA, companies are better equipped to rank failures by statistical criticality and prioritize actions that improve mission reliability.
FMEA vs. FMECA—Key differences
While FMEA and FMECA both target risk management and remediation, they do so in different ways. Here’s a look at how they stack up.
Category | FMEA | FMECA |
Purpose | Identify and prioritize failure risks | Identify, quantify and rank failure criticality |
Risk assessment method | RPN (Severity x Occurrence x Detection) | Quantitative criticality calculations |
Use of failure rate data | Typically qualitative | Often quantitative |
Complexity level | Moderate | Advanced |
Best used for | General manufacturing risk analysis | High-risk, safety-critical systems |
Data requirements | Cross-functional input | Statistical reliability data |
Common industries | Automotive, general manufacturing | Aerospace, defense, energy and complex systems |
Output | Prioritized action list | Criticality-ranked failure modes |
Focus | Prevention and process improvement | Reliability monitoring and mission assurance |
When should you use FMEA?
Several common scenarios benefit from the use of FMEA. They include:
- New product or process launches: New products and processes often introduce new risks. FMEA analysis helps spot these risks before they become production line problems. Apply FMEA during design and testing phases before full production.
- Identifying quality defects: FMEA can identify quality defects and tie these defects to specific organizational risks, allowing manufacturers to create a targeted response strategy.
- Improving overall equipment effectiveness (OEE): Even small amounts of unplanned downtime can significantly impact OEE. FMEA enables early prediction of possible downtime causes, enabling proactive maintenance.
- Reducing scrap and reworks: Scrap and reworks are costly. FMEA can track production line processes to help pinpoint where quality issues are occurring.
- Equipment reliability improvement: FMEA provides a framework to monitor risk trends and identify recurring failure patterns over time.
- Continuous improvement initiatives: FMEA sets the stage for continuous improvement initiatives. Equipped with risk and impact data, teams are better prepared to design maintenance strategies that solve high-priority problems.
- Situations where failure probability data is limited: Not all failure data is obvious. FMEA measurements help quantify failure risk and provide a clear path forward.
When should you use FMECA?
FMECA should be used in situations where deeper mode criticality analysis is required, such as:
- Safety-critical environments: Environments that include high-risk machinery such as saws and blades, high-temperature processes or hazardous chemicals benefit from FMECA analysis to identify critical risks.
- Highly regulated industries: FMECA also supports operational compliance objectives for highly regulated industries such as pharmaceuticals, food and beverage, and aerospace.
- Complex systems with cascading failure impacts: Some production lines are largely independent. Failure of one machine is an isolated incident that can be repaired with minor disruptions. Other systems are more complex, relying on interconnected systems that only function in sequence. In this case, even a single failure can lead to cascading downtime. FMECA enables proactive identification and prioritization of high-impact failure risks.
- Facilities where downtime has significant cost implications: For large manufacturers, even an hour of downtime can cost hundreds of thousands or millions of dollars. With FMECA, teams can target and reduce high-risk downtime causes.
- Scenarios that require statistical reliability modeling: Highly specialized components often require statistical reliability monitoring. FMECA provides key baseline data to improve statistical accuracy.
How FMEA and FMECA support maintenance strategies
Both FMEA and FMECA help support maintenance strategies.
First, they can identify high-risk components that may require more frequent machine health monitoring and maintenance. This reduces the chance that these components will fail and equips maintenance teams with the data they need to carry out in-depth root cause failure analysis (RCFA).
FMEA and FMECA also underpin predictive maintenance programs. By ranking risks before they occur, organizations can identify which assets are most likely to fail and create maintenance strategies designed to minimize these risks. Common strategies include bi-weekly or monthly maintenance, quarterly planned downtime for more thorough evaluations, and real-time data tracking and analysis using tools such as computerized maintenance management systems (CMMS). This data can then be leveraged to inform MRO spare parts strategies to ensure companies have components on hand to address high-likelihood or high-impact events.
In addition, FMEA and FMECA metrics help improve metrics such as mean time between failure (MTBF) and mean time to recovery (MTTR) because they lay the groundwork to identify root causes rather than symptoms.
The result is a firm foundation for reliability-centered maintenance (RCM) that targets top priorities and aligns maintenance budgets with risk exposure realities.
The business impact of effective failure analysis
Manufacturers can expect measurable business improvements tied to FMEA and FMECA metrics, including:
- Reduced high-impact failure rates
- Improved equipment uptime
- Enhanced safety performance
- Lowered lifecycle costs
- Increased regulatory compliance
- Streamlined capital planning
Strengthen reliability with industrial maintenance services
Effective use of FMEA and FMECA requires the right approach. Data alone isn’t enough; organizations also need technologies, services and strategies that enable real-time data collection and long-term maintenance planning.
Partnerships with experienced industrial maintenance services providers improve risk analysis and provide access to actionable data. Additional benefits of industrial maintenance services include:
- Reliability-centered maintenance expertise
- Integration of predictive maintenance solutions
- Deployment of condition monitoring tools
- Development of comprehensive maintenance strategies
- Analytics for risk-based decision making
- End-to-end maintenance services to improve visibility
FMEA and FMECA provide structured insight into failure risks and maintenance priorities. While both offer benefits, choosing the right approach for your industry and application can increase the value of risk analysis.
Whether you use FMEA, FMECA or a combination approach, partnering with a full-service maintenance provider enables the accuracy and visibility required to make data-driven risk decisions and build reliability-centered maintenance strategies.
Strengthen your risk analysis approach with ATS.
