The integration of high-performance FMEA (Failure Mode, Effect and Criticality Analysis) software solutions has become essential to meet the growing demands of the aeronautics and aerospace industry. Indeed, the importance of this risk analysis method is becoming ever more crucial in ensuring the reliability and safety of the complex systems used in the aerospace industry.
In this interview, Bernard Moret, Head of Central Methods and Digital Transformation at Safran, shares his experience of changing customer requirements, the growing importance of complete process FMEAs, and the solutions implemented to optimize this essential practice. In particular, he explains the obstacles involved in homogenizing FMEA practices across the company, as well as the benefits of using specialized tools, such as Skill FMEA Pro from Skill Software. This discussion highlights the strategic and operational challenges Safran faces in guaranteeing the reliability and compliance of its processes.
Could you introduce yourself and the challenges you face in terms of FMEA?
"As Head of the Methods Department, our main challenge is to homogenize FMEA practices across the company. Previously, we used a light approach, but the current requirements of our customers and our processes now require us to carry out complete process FMEAs. While we have some experience of carrying out FMEAs using Excel files, this method has major drawbacks: lack of standardization of designations, difficulty in reusing data, and complexity in finding information."
Methods Managers in high-tech companies like Safran face complex FMEA challenges. These issues are particularly critical in the aeronautics and aerospace sectors, where safety and reliability are paramount.
One of the main challenges is managing the growing complexity of systems and processes. Modern aeronautical products integrate numerous interconnected subsystems, multiplying the number of potential failure points to be analyzed. This complexity calls for a more sophisticated and exhaustive FMEA approach.
Another major challenge is adapting to new industry standards and regulations. Standards such as IATF 16949 for the automotive industry, or IAQG for the aerospace industry, impose strict requirements in terms of FMEA. Methods Managers must constantly update their practices to remain compliant.
Knowledge capitalization and reuse also represent a major challenge. Without a centralized system, it is difficult to capitalize on previous FMEA analyses, which can lead to redundancies and inconsistencies between different sites or projects within the company.
Furthermore, the integration of FMEA into a continuous improvement approach is becoming increasingly important. This involves not only carrying out initial analyses, but also updating them on a regular basis, and following up any corrective action taken. This dynamic approach is essential to maintain the effectiveness of the FMEA process over the long term.
Finally, the digital transformation of the aeronautical sector poses new challenges in terms of FMEA. The integration of technologies such as the Internet of Things (IoT) and artificial intelligence (AI) into products and manufacturing processes means that risk analysis methods need to be adapted.
To meet these challenges, Methods Managers need to adopt advanced FMEA tools and methodologies, capable of managing complexity, ensuring regulatory compliance, facilitating knowledge capitalization and integrating into a company-wide continuous improvement approach.
What were the initial reasons for choosing Skill Software as your FMEA software publisher?
"Our main objective was to acquire a tool to optimize our FMEA work. After evaluating several solutions, including Skill FMEA Pro and another competitor's software, we opted for the latter. The decisive criteria were the ease of use, and the intuitive graphic interface with its many visuals and colors, particularly well suited to our production needs."
The importance of user-friendly, attractive FMEA software should not be underestimated in today's industrial context. An intuitive and visually appealing user interface plays an important role in the adoption and effective use of the tool by teams. Indeed, it considerably reduces the training time required, and enables teams to concentrate quickly on the analysis of failure modes and their effects. A well-designed graphical interface, with clear visuals and distinct color codes, helps users to quickly identify critical points and efficiently navigate through the various sections of the FMEA.
What's more, simplicity of use facilitates wider adoption within the company. Complex software can discourage users and limit their use to a small group of experts. Ergonomic software, on the other hand, encourages wider participation and facilitates collaboration between different teams, whether in design, production or quality. This is particularly important in complex industrial environments, where interdisciplinary collaboration is essential to identify and mitigate risks.
In addition, the speed with which FMEA software can be implemented is a significant advantage. Companies can quickly integrate the tool into their existing processes without disrupting their operations, a particularly important point in sectors such as aerospace or automotive, where time-to-market is tight and compliance with quality standards imperative.
Another major technical aspect is the software's ability to manage and organize complex data in a clear and accessible way. For example, features such as the visualization of product and process structures in the form of trees or networks enable a better understanding of the interrelationships between different components and their failure modes. This not only facilitates analysis, but also the communication of results and corrective actions to the whole team.
Can you tell us about the benefits and results of using Skill Software's solution?
"The benefits have become obvious since we dedicated a full-time person to its use. The time saved is considerable, mainly thanks to the generic FMEA function which avoids redundant work. We estimate that we've cut the time needed to complete FMEAs by a factor of three. The software offers perfect synchronization between FMEAs, monitoring plans and manufacturing data, guaranteeing optimum document consistency. This software fully meets our expectations."
One of the main benefits of using specialized FMEA software is the reduction in the time needed to carry out analyses. According to experience feedback, the use of these tools can reduce the time spent creating FMEA studies by up to 50% in the first few months following training. This efficiency is mainly due to the automation of many repetitive tasks, such as generating reports and updating databases, as well as to the possibility of reusing generic FMEAs for different projects.
An FMEA software solution also ensures optimum consistency between the various documents and elements of FMEA management. These tools are able to centralize all FMEA data in a single platform, facilitating communication and collaboration between the different teams, whether in R&D, quality, engineering, production or maintenance. This centralization ensures that all stakeholders work with up-to-date and consistent information, reducing the risk of errors and inconsistencies.
In addition, specialized FMEA software offers advanced features for managing action plans and performance indicators. For example, they can generate dynamic HTML documents, send reminder emails and provide tracking indicators for action plans. These features facilitate proactive monitoring of corrective and preventive actions, ensuring continuous process improvement.
Another key benefit is the software's ability to manage and organize libraries of data, such as failure modes, causes and means of prevention. These libraries can be customized and enriched over time, facilitating the standardization of analyses and the reuse of acquired knowledge. This contributes to better knowledge management within the company, and increases the effectiveness of FMEA analyses.
Which elements of the Skill FMEA Pro solution and Skill Software support do you find most beneficial?
"The colorful graphics, which enable us to identify the status of our FMEAs very quickly, and the fact that it's relatively easy to get to grips with.
Skill Software's customer support is excellent. We were given several weeks' support during the initial installation, and they were able to answer all our questions. It's a company on a human scale, where availability and responsiveness are always present. Their personalized approach enabled us to quickly gain proficiency with the tool, thanks in particular to the level 2 training which offers advanced mastery of the software. Skill Software is a company that fits us perfectly."
Customer support that is attentive, available and responsive is essential for maximizing the efficiency and autonomy of FMEA software users. Such support considerably reduces software training and implementation times. Users can quickly get answers to their questions and solutions to their problems, accelerating their learning curve. This is particularly important for companies that need to integrate new tools without disrupting current operations.
What's more, customer support that takes account of users' specific needs enables greater customization of the software. This includes assistance in configuring specific functionalities or adapting modules to meet particular business requirements. This customization ensures that the software is used optimally and meets operational needs perfectly.
Reactive support also enables proactive problem management. Rather than waiting for users to encounter difficulties, support can anticipate needs and propose solutions before problems become critical. This minimizes service interruptions and maintains business continuity. This accessibility is essential to guarantee fast, efficient assistance, whatever the context or urgency of the problem encountered.
Good customer support not only solves technical problems, it also passes on knowledge to users. This includes in-depth training, webinars and detailed user guides. By gaining a better understanding of the software, users become more autonomous and able to solve many of the problems they encounter themselves.
Finally, regular interaction with a responsive support team helps to gather valuable feedback, which can be used to continually improve the software. Effective support acts as a bridge between users and developers, facilitating continuous product improvement.
In a few words, how would you describe Skill Software and their Skill FMEA Pro solution?
"Ease, reliability and support. Ease of use is demonstrated by the fact that it's quick and easy to get to grips with. Reliability is demonstrated by the absence of major bugs. And customer support is exemplary, with a constant, responsive presence from the Skill Software's team."
