[FMEA feature] FMEA Process in Skill FMEA Pro

Published: February 2, 2026

It is possible to synchronize the Product FMEA with the Process FMEA, or to run only one type of FMEA. Process FMEAs are managed via a simple, intuitive interface. You build manufacturing mimics, deploy risk analyses and then create action plans to reduce criticality values. Workstation data sheets, perfectly in line with the flowchart, will be created automatically.

The different types of FMEA

Failure Mode, Effect and Criticality Analysis (FMEA) is a proactive method used to anticipate and prevent potential failures in various industrial fields. It can be applied effectively in a variety of ways, depending on the subject under analysis.

FMEA is not monolithic. It comes in different versions, each with a distinct focus:

- Product (or Design) FMEA: This focuses on the potential failures of a product, often due to its specifications or intrinsic design.
- Process FMEA: This variant focuses on potential failures during the manufacturing or assembly phases of a product.
- System FMEA: Oriented towards the analysis of failures in a system as a whole, this method is often favored during the initial design phases.

Each of these types aims to prevent specific risks and guarantee reliability in different areas of industry.

Process FMEA

Definition

Unlike Product FMEA, which focuses on the product itself, Process FMEA looks at manufacturing procedures and processes. Its aim is to identify and assess the potential risks associated with the various manufacturing and processing stages, so as to guarantee reliable, high-quality production.

Objectives

The main objective of Process FMEA is to ensure the reliability of manufacturing processes. This includes :

1. Early detection of failures or errors in the production process.
2. Improving the quality of finished products by ensuring that each stage of the process is optimized.
3. Reducing costs by avoiding costly production errors.
4. Increase production efficiency by identifying bottlenecks and other inefficiencies.

Application steps

There are several key stages in the application of Process FMEA:

- Process step identification: detailed mapping of all steps in the manufacturing process.
- Risk assessment: Identification of potential failures at each stage, and evaluation of their impact and probability.
- Prioritization: Ranking of identified risks according to severity and probability.
- Definition of corrective actions: Development of strategies to mitigate or eliminate identified risks.
- Implementation and monitoring: Application of corrective actions and regular monitoring to ensure their effectiveness.

Advantages and disadvantages

Advantages:

1. Continuous improvement of production processes, resulting in higher quality finished products.
2. Cost reduction by preventing costly production errors.
3. Better understanding of processes, making it easier to train new employees.
4. Increased stakeholder confidence thanks to reliable, quality production.

Disadvantages :

1. Requires investment of time and resources to conduct a full analysis.
2. Changes made to mitigate risks may sometimes entail additional costs or changes to established processes.
3. As with Product FMEA, the effectiveness of the analysis depends largely on the expertise and diligence of the team involved.
4. Risk of over-analysis, where too much time is spent on analysis to the detriment of actual production.

Like Product FMEA, it should be noted that Process FMEA is a powerful tool for optimizing production processes, but like any tool, its success depends on how it is used. Rigorous and well-informed implementation can have a significant impact on production quality and efficiency.

Criteria	Product FMEA	FMEA Process
Main objective	Identify and prevent potential product failures	Analyze and optimize process steps
Areas of application	Aerospace, automotive, electronics	Food, chemical, manufacturing
Expected results	Improved product reliability and quality	Reduced costs and downtime, improved productivity
Application examples	Design of a medical device	Improvement of a plant's packaging line
Main benefit	Reduce risks associated with the product before it goes into production	Continuous optimization of processes for greater efficiency

The importance of software like Skill FMEA Pro

In today's world of ever-increasing product and process complexity, the use of software such as Skill FMEA Pro has become virtually indispensable.

Its advantages are numerous:

- Standardization: provides a framework to ensure that analysis is carried out in a uniform way.
- Database: Stores information for future use, avoiding redundant work.
- Real-time updating: As data is modified or updated, changes are immediately reflected, ensuring a constantly up-to-date analysis.
- Ease of collaboration: Several team members can work simultaneously on an analysis, promoting the sharing of knowledge and skills.
- Integrated training: One of the greatest advantages of Skill FMEA Pro is its training module. Both novice and experienced staff can benefit from integrated training sessions, tailored to different skill levels. These training sessions ensure that every team member understands not only how to use the software, but also the fundamentals of FMEA.

The effectiveness of FMEA is strongly influenced by the quality of its implementation. Tools like Skill FMEA Pro, combined with thorough staff training, can help maximize this effectiveness, while minimizing the associated risks.