Process FMEA analysis: failure prevention in gear industry

aprile 10, 2024

You will surely have been thinking about how to maximize quality and minimize risks several times, without having a precise answer. The adoption of the FMEA process analysis tool is the answer to this fundamental question.
In gear industry, quality and reliability are essential to ensure the correct functioning of machinery and devices. Any defect can cause significant problems and compromise the performance of the final product.

Origins and development of FMEA

Failure Mode and Effects Analysis (FMEA) was born in the American aerospace industry of the 1940s and it was initially intended to improve the safety and reliability of aircraft. Over the years, FMEA has been adapted for use in various industries, including gears, to identify and prevent possible failures early in the production process.

Application of process FMEA in the gear sector

Applying FMEA process in gear manufacturing means to focus on every single production phase, from raw material processing to final assembly. This method allows you to identify potential risks of failure, which may be linked to variations in materials, manufacturing errors, and general process inefficiencies.

Operational steps of the process FMEA

1. Identification of process steps

The first step is to outline each stage of the gear manufacturing process, including operations such as milling, turning, heat treatments and quality controls.

2. Identification and evaluation of potential failure risks

For each identified stage it is necessary to evaluate potential failure risks, such as sizing errors or surface defects. This evaluation is crucial to anticipate problems before they compromise the final product.

3. Assignment of risk scores

Each identified risk is evaluated based on three criteria: severity, probability of occurrence and detectability. Through these scores, it is possible to prioritize the corrective actions necessary to mitigate the risk.

4. Identification of corrective actions

Finally, based on the risk scores, the team develops and implements corrective actions to reduce or eliminate risks. These may include process changes, technology upgrades, or improvements in quality control procedures.

Process FMEA analysis is essential in the gear industry to prevent failures that could have negative impacts on both production and the final product. Through careful identification and mitigation of risks, companies not only ensure a high-quality product but also maintain competitiveness and customer satisfaction in the current market. Do you want more information on how FMEA Analysis can be implemented in your company? Contact us for detailed advice.