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Failure mode and effects analysis is the process of reviewing as many components, assemblies, and subsystems as possible to identify potential failure modes in a system and their causes and effects. For each component, the failure modes and their resulting effects on the rest of the system are recorded in a specific FMEA worksheet. It was one of the first highly structured, systematic techniques for failure analysis. An FMEA is often the first step of a system reliability study.

Unfortunately, creating Process FMEA’s is usually a manual, time-intensive process with a cross-functional team gathered in a conference room. The information used in the analysis is often anecdotal or estimated. The analyses often get out of date very quickly once they are complete.

We can help you create ever-green Process FMEA’s using Industry 4.0. Using these tools, the FMEA can be continually updated based on information directly from the shop floor. They can show more information than ever before. And they can be used as a management tool for when exceptions happen in production.

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A value stream map is a visual tool that displays all critical steps in a specific process and quantifies the time and volume taken at each stage. Value stream maps show the flow of both materials and information as they progress through the process.

Unfortunately, creating value stream maps is usually a manual, time-intensive process with a cross-functional team gathered in a conference room. The times used in the map are estimated. The maps often get out of date very quickly once they are complete.

We can help you modernize your Value Stream Maps using Industry 4.0. Using these tools, the maps can be continually updated based on information directly from the shop floor. They can show more information than ever before. And they can be used as a management tool for when material flows change on the ship floor.

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The goal for this series of posts is this: How can we improve visual controls so that we can see the real-time status of every process, from anywhere. To achieve that goal will require change to how things have been done in traditional manufacturing or in lean manufacturing environments. By the end of the series, we should understand why this is beneficial and how to achieve that goal.

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This is Part 1 of our series on this topic. You can see the rest of the posts through these links: IntroductionWho What When Where Why & How5 Why’sFishbone (Ishikawa) DiagramCustomer ExampleGraphical AnalysisFailure Modes & Effects Analysis (FMEA)Statistical Analysis of FactorsLessons Learned You can also watch the webinar recording on this topic Introduction We are […]

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This is part 1 in our series on Improving Kaizen with Industry 4.0. To view the other sections, use these links: OverviewTypical Kaizen StepsStep 1: Identify the ProblemsStep 2: Analyze the ProcessStep 3: Create SolutionsStep 4: Test the SolutionsStep 5: Measure and Analyze ResultsStep 6: Standardize the Solution You can also watch the webinar recording. […]

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This is Part 8 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 7 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 6 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 5 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 4 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 3 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 2 of our series on this topic. You can see the rest of the posts through these links: IntroductionHow Can Industry 4.0 HelpWhere to Get the Data (pt 1)Where to Get the Data (pt 2)Other Industry 4.0 ImpactsThe FMEA as a Living DocumentLessons LearnedClosing Thoughts You can also watch the webinar recording […]

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This is Part 9 of our series on this topic. You can see the rest of the posts through these links: IntroductionMapping Process OverviewTypical Mapping OutputsManual or Digital?Benefits of Going to Digital (pt 1)Benefits of Going to Digital (pt 2)How to Go Digital (pt 1)How to Go Digital (pt 2)Closing Thoughts You can also watch […]

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This is Part 8 of our series on this topic. You can see the rest of the posts through these links: IntroductionMapping Process OverviewTypical Mapping OutputsManual or Digital?Benefits of Going to Digital (pt 1)Benefits of Going to Digital (pt 2)How to Go Digital (pt 1)How to Go Digital (pt 2)Closing Thoughts You can also watch […]

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