Not every risk starts as a defect.
Some begin as:
• Human Error
• Broken Tool
• Contamination
• Loose Part
• Wrong Setting
• Leak
• Misalignment
• Worn Fixture
• Machine Downtime
• Missing Detection
• Weak Control Plan
• Improper Maintenance
And if these are not identified early, they slowly become:
• Defect
• Scrap
• Rework
• Customer Complaint
• Downtime
• Warranty
• Recall
That is why FMEA is not just a document for audits.
It is an umbrella that protects the process before the storm arrives.
A good FMEA does not predict the future perfectly.
It simply forces the team to think before the problem happens.
The stronger the thinking, the lower the firefighting.
How often does your team revisit FMEA after launch?
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