In this expert interview, a Preventive Quality Manager from a water meter manufacturer discusses the challenges of implementing FMEA (Failure Mode, Effect and Criticality Analysis) to ensure product reliability and performance. The challenges are many: complying with stringent regulatory requirements, meeting increasingly demanding customer expectations, while guaranteeing the durability and accuracy of meters under difficult conditions.
In this interview, the expert also shares the evolution of the FMEA process within his company, marked by the transition from Excel to a dedicated software package, Skill FMEA Pro. This change made it possible to structure and facilitate analyses, in particular by ensuring better traceability of risks and more reactive follow-up of corrective actions.
Could you introduce yourself and the challenges you face in terms of FMEA?
"I'm in charge of preventive quality, where we manufacture water meters and radio modules enabling data transmission to water distribution providers. These products meet strict requirements, both in terms of regulations and customer expectations, which are becoming increasingly specific.
Faced with these constraints, the main challenge is to control the risks associated with development and production. We use FMEA as a preventive method to anticipate potential problems and guarantee the quality of our products. Even if our certifications do not require it, we have chosen to integrate this approach into our internal strategy, as it translates into measurable benefits in terms of product reliability and performance, without our customers needing to explicitly demand it."
Water meter manufacturers face stringent requirements linked to regulatory compliance, technical performance and long-term reliability. These products must withstand demanding conditions, such as pressure variations, exposure to water and corrosive agents, while guaranteeing consistent measurement accuracy. A failure can result in high costs for operators or end-users, hence the importance of a methodical approach to identifying and controlling risks.
FMEA is a structured method which analyzes possible failure modes, assesses their criticality and prioritizes the necessary corrective or preventive actions. For water meters, this approach takes into account multiple issues, including compliance with international standards, the integration of connected technologies (IoT) and data security. This enables us to anticipate potential problems linked to the mechanical, electronic and digital aspects of our products.
By integrating FMEA into the design and production process, manufacturers improve the robustness and reliability of their products, while reducing the costs associated with breakdowns and recalls. This proactive strategy also enhances customer satisfaction and the ability to adapt to increasingly complex requirements in a constantly evolving market.
What were the initial motivations for choosing Skill FMEA Pro as your FMEA software?
"Before 2014, we were using Excel to carry out our FMEAs, but this tool had limitations, particularly in terms of methodology and follow-up. During our search for solutions, two service providers were shortlisted. Technically, their offers were comparable, but the ergonomics of the Skill FMEA Pro interface and the quality of the contact with their teams made the difference.
Since its acquisition, the software has been progressively integrated, first in France, then internationally, with current implementation at three sites. This wider adoption is testimony to the value it brings to our processes."
The ergonomics of a user interface plays a decisive role in the efficiency and productivity of FMEA software users. A well-designed interface reduces cognitive load, minimizes errors and speeds up the execution of the complex tasks inherent in failure mode analysis. Ergonomic design principles, such as simplicity, visual consistency and intuitive navigation, contribute to an optimal user experience, facilitating the adoption and regular use of the software by teams. In the specific context of FMEA, an ergonomic interface promotes a better understanding of analysis processes, faster identification of potential risks and more informed decision-making regarding corrective actions to be implemented.
The quality of customer relations is another major differentiating factor when choosing a FMEA software provider, particularly when the technical offerings are similar. A provider offering responsive and competent customer support, capable of understanding the company's specific needs and proposing appropriate solutions, brings significant added value. This relationship of trust not only facilitates the initial implementation of the software, but also its wider deployment, as evidenced by the international expansion mentioned. The supplier's ability to provide ongoing technical support, customized training and regular updates in line with changes in standards ensures the long-term viability and effectiveness of the FMEA solution.
Can you tell us about the benefits and results of using Skill Software's solution?
"The main advantage lies in the structuring it brings to the FMEA method. Unlike Excel, which relies solely on the user's knowledge, Skill FMEA Pro guides users through the stages of analysis, guaranteeing rigorous application of the methodology.
The software also facilitates collaboration, particularly with the validation department. We can extract targeted lists of tests or action plans directly from the FMEA, optimizing their follow-up and implementation. What's more, the automatic updating of critical scores according to the status of action plans is a precious time-saver, compared with manual processes in Excel.
What's more, Skill FMEA Pro integrates well with our internal tools, thanks to export functionalities to our usual formats (Excel). This makes for smooth adoption by the teams and guarantees continuity in our practices."
Using FMEA software rather than Excel offers significant advantages in terms of structuring and methodology. Whereas Excel requires manual management of each stage of the analysis, dedicated software offers a structured framework that guides users through the various phases of the FMEA, from identifying failure modes to assessing their criticality. This integrated framework ensures that teams follow a standardized process, minimizing the risk of error and guaranteeing consistent application of the methodology, which is difficult to achieve with Excel, where flexibility can turn into lack of rigor.
Furthermore, FMEA software improves inter-departmental collaboration, facilitating information sharing and simplifying the management of corrective and preventive actions. When an analysis is performed in the software, data can be extracted and filtered for sharing with other departments, such as validation or testing. This enables targeted lists of action plans or tests to be created, which are then monitored in real time and updated automatically as progress is made. This automation of critical dimension updates, for example, ensures that the whole process moves smoothly, unlike Excel, where every change has to be manually reflected in several documents, increasing the risk of inconsistency.
The ability of FMEA software to integrate seamlessly with existing in-house tools is another important advantage. Many companies already use standardized data management systems or reporting formats, such as Excel, for their analysis and monitoring. Dedicated software often offers export and integration features that guarantee a smooth transition, while maintaining continuity with existing practices. Adoption of the software is thus facilitated, as users can continue to work in a familiar environment while taking advantage of the software's advanced features to optimize their risk analysis and monitoring processes.
Which elements of the Skill FMEA Pro solution and Skill Software support do you find most beneficial?
"The ability to capitalize on generic FMEAs to generate specific versions is a real asset. In our case, where the products share common characteristics, this simplifies the work considerably. What's more, the statistical tools included enable us to quickly identify points of vigilance, such as under-analyzed causes of failure or characteristics not associated with risks.
Skill Software's customer support is highly responsive and competent. Every time we've needed assistance, we've been given a quick, clear answer. The relationship is fluid and pleasant, and their team has a perfect command of their product and the associated business issues. This is a real strength compared with other software publishers."
Capitalizing on FMEA data allows us to structure and centralize the information resulting from analyses, thus facilitating the creation of specific FMEAs based on generic models. For water meter manufacturers, whose products have similar characteristics but technical or functional variations, this approach reduces implementation time and guarantees consistency in risk assessment. It also optimizes the historization of information, enabling us to take advantage of feedback and reinforce the robustness of future analyses.
The integration of statistical tools within a FMEA solution offers an additional advantage by highlighting trends or anomalies in the analyses. For example, the identification of insufficiently explored causes of failure, or of characteristics not associated with risks, enables gaps to be detected in the assessment. This targeted information helps teams to refine their analyses and strengthen validation and design processes.
A responsive and competent support service plays a key role in the effective implementation and operation of FMEA software. The availability of experts capable of responding rapidly to specific problems guarantees business continuity, particularly in complex technical environments. Support's ability to understand business issues and user needs fosters a relationship of trust, contributing to the success of projects and better integration of FMEA methodology within the company.
In a few words, how would you describe Skill Software and their solution?
"It's very good software and really guides the user to use the right method."
