In the automotive sector, Tier 2 subcontractors face increasing challenges in terms of risk management and compliance with quality standards. FMEA (Failure Modes, Effects and Criticality Analysis) is an essential tool for meeting these requirements. In this context, the adoption of specialized software solutions for FMEA management is becoming a strategic issue for these companies.
In this interview with Microtechnic, Denis Faillon - Quality Development Manager, and Ichrak Hajji - Quality Engineer, shed light on their experience in implementing a FMEA software solution - Skill FMEA Pro. This interview highlights the challenges encountered, the benefits obtained and the key success factors in adopting such a tool. In particular, they discuss the importance of the software's ergonomics, the quality of technical support, and the impact on the company's productivity and credibility with its customers. This analysis offers insights for industry professionals facing similar issues.
Could you tell us about yourself and the challenges you face when it comes to FMEA?
"Microtechnic is a company founded in Monaco in the 50s, specializing in the design and development of products for the automotive industry, mainly in plastic injection. We have three plants, two in Tunisia and one in the Czech Republic. Our head office and design office remain in Monaco.
As a Tier 2 supplier, we have to comply with IATF standards and automakers' requirements, which are becoming increasingly stringent. FMEA is therefore a very important risk management tool in our industry. And we needed to modernize our approach, moving from Excel files to a more robust and structured solution to meet our customers' expectations and standards requirements."
Subcontractors play an important role in the automotive industry's supply chain. These companies face significant challenges, particularly when it comes to FMEA. In fact, they have to comply with IATF 16949 standards, which are specific requirements of automobile manufacturers (OEMs). These standards aim to guarantee consistent quality and minimize risks in the supply chain. OEM requirements are becoming increasingly stringent, forcing subcontractors to adopt more sophisticated and robust risk management methods.
In response, FMEA is a relevant tool for identifying and mitigating potential risks in production processes and products. The aim is to detect potential failure modes, assess their impact and implement corrective actions to prevent these failures. This improves the reliability and safety of products supplied to OEMs.
The harmonization of FMEA standards between the AIAG (Automotive Industry Action Group) and the VDA (Verband der Automobilindustrie) has revolutionized risk management in the automotive industry. This harmonization has reduced discrepancies and improved the consistency of risk management practices worldwide. Subcontractors need to familiarize themselves with these new harmonized standards if they are to remain competitive and meet OEM expectations.
Historically, many subcontractors used Excel files to carry out their FMEA analyses. However, this approach has limitations in terms of robustness, traceability and collaboration. Modernization towards more structured and integrated software solutions has become essential to meet customer expectations and standards requirements. These solutions enable better data management, more in-depth analysis and more effective collaboration between teams.
Furthermore, the growing complexity of the supply chain exposes subcontractors to risks such as production interruptions, material shortages and logistical failures. Proactive risk management, including FMEA, is therefore important to anticipate and mitigate these disruptions. Subcontractors must also ensure supply chain transparency and resilience to meet OEM requirements.
What were the initial reasons for choosing Skill Software as your FMEA software provider?
"Several factors guided our choice. First of all, the ergonomics of the Skill FMEA Pro software won us over. Secondly, the quality of our relationship with the Skill Software representative was decisive. Finally, the ratio between the price, which is certainly substantial, and the services offered by Skill in comparison with the competition, tipped the scales in our favor. After consulting 4 or 5 publishers on the market, Skill stood out as the solution best suited to our needs."
When it comes to FMEA, the importance of a visually appealing and ergonomic software solution cannot be underestimated. A well-designed, intuitive user interface plays an important role in facilitating learning and increasing user efficiency. In an environment where teams have to adapt quickly to new tools and methods, careful ergonomics can reduce learning times and boost productivity.
What's more, an ergonomic interface promotes fluid navigation between different functions, enabling users to carry out complex analyses without getting lost in menus or complicated commands. This ease of use means fewer errors and less downtime, contributing to more effective risk management. In addition, data visualization, through graphical representations of failure modes and their criticality, facilitates understanding of risks and enables rapid, informed decision-making.
Beyond the technical aspects, the commercial approach and human relations are also decisive factors in the choice of a FMEA software solution. The quality of the relationship with the software publisher's representatives contributes to establishing a relationship of trust, essential for a lasting partnership. A sincere, human relationship fosters an environment conducive to collaboration, where technical support and personalized assistance become invaluable assets for rapid problem-solving and ongoing adaptation to the company's specific needs.
It's also important to consider the relationship between cost and the benefits offered by the chosen solution. Although the price may seem high, the benefits in terms of risk reduction, quality improvement and compliance with standards often justify the investment. A well-chosen solution can also generate long-term savings by avoiding the costs associated with defects and delays. Evaluating the different options available on the market enables us to select the one that offers the best value for money, taking into account not only ergonomics and functionality, but also customer support and understanding of the company's specific needs.
Can you tell us about the benefits and results of using Skill Software's solution?
"The main benefit is the time saved in managing our PPAP files. Although the initial learning curve is time-consuming, once we've mastered it, the software enables us to optimize our operations considerably.
What's more, the use of specialized software strengthens our credibility with our customers, demonstrating that we are serious about risk management. This tool also helps us to adapt more effectively to new customer requirements, and to emerging risks in our industry."
The use of a software solution specialized in FMEA management offers many technical and operational advantages for companies in the automotive sector, particularly for subcontractors.
A major advantage of these solutions is the time they save in managing PPAP (Production Part Approval Process) files. Once the learning phase is over, these software packages enable considerable optimization of FMEA-related operations. This optimization translates into a significant reduction in the time spent creating, updating and managing risk analyses.
These specialized tools also offer advanced features that automate many time-consuming tasks. For example, they can automatically generate standardized reports, update criticality indices in real time, and facilitate collaboration between the different teams involved in the FMEA process. These features not only save time, but also reduce human error and improve the consistency of analyses.
The use of a tool dedicated to FMEA management considerably enhances a company's credibility with its customers. Indeed, these software solutions demonstrate a serious commitment to risk management and product quality. They offer complete traceability of analyses and corrective actions, which is particularly appreciated during customer audits or certifications.
Another important technical advantage is the ability of these software packages to integrate different types of FMEA (product, process, resources) within the same platform. This integration provides a global view of risks and facilitates strategic decision-making in terms of quality management.
Which elements of the Skill FMEA Pro solution and Skill Software support do you find most beneficial?
"Skill Software's support is excellent. They provided four days of on-site training in Tunisia, followed by online follow-up sessions. Their responsiveness is remarkable: we generally get answers to our questions within a day, or within 2-3 days at the latest for more complex problems. They have even adapted the software to meet some of our specific requirements, which testifies to their flexibility and commitment to their customers.
Our experience with Skill Software and Skill FMEA Pro has been very positive. The software has brought modernization and rigor to our document management. Despite a steep initial learning curve, the benefits in terms of automation, process structuring and compliance with industry requirements are undeniable. The solution is helping us to future-proof our business in a demanding sector."
Initial face-to-face training on FMEA software enables complete and intensive immersion in the use of the software, facilitating in-depth understanding of its functionalities and specific applications. Trainers can adapt their teaching in real time to the questions and difficulties encountered by participants, ensuring optimum assimilation of concepts.
In addition, face-to-face training encourages direct interaction between trainers and users, enabling hands-on demonstrations and interactive exercises. This approach is particularly beneficial for users who are new to FMEA, or who are switching from manual systems to automated software. The ability to ask questions and receive immediate answers helps to clarify complex points and boost users' confidence in their ability to use the software effectively.
After initial face-to-face training, additional remote sessions can be organized to go into greater depth on specific aspects of the software. This hybrid approach maximizes training effectiveness by offering learning flexibility. Users can focus on particular modules or functionalities that require additional attention, while benefiting from the expertise of remote trainers.
Remote sessions also provide ongoing support and answer questions that arise during day-to-day use of the software. They provide an opportunity to review and consolidate the knowledge acquired during initial training, while enabling rapid adaptation to software updates or new industry requirements.
The responsiveness of FMEA software publishers to customer support requests is therefore a major factor in ensuring optimum use of the software. Fast, efficient support minimizes work interruptions and enables technical problems or questions of use to be resolved quickly. Software publishers need to be able to provide answers within short timescales, ideally within a day for simple questions, and within 2-3 days for more complex problems.
This responsiveness demonstrates the company's commitment to its customers, and helps build confidence in the software. It also makes it possible to adapt the software to users' specific needs, offering customized solutions and integrating additional functionalities where necessary. Publishers' ability to respond quickly and flexibly to customer requests is a key indicator of customer service quality and software reliability.
In a few words, how would you describe Skill Software and their Skill FMEA Pro solution?
"It's a structured application that makes our jobs easier. Skill Software's customer support and responsiveness are really very satisfying."
