In the demanding automotive industry, compliance with IATF 16949 and ISO 9001 standards is essential to ensure product quality and reliability. Equipment manufacturers must not only meet international standards, but also satisfy the specific requirements of each manufacturer. In this context, FMEA (Failure Mode, Effect and Criticality Analysis) processes play a central role in risk management and defect prevention. To optimize these processes, it is essential to invest in dedicated software. These tools facilitate the standardization of risk studies, improve the effectiveness of internal communications and guarantee the traceability of corrective actions.
In this interview, Loïc Rustaut, Quality Correspondent for the automotive forging industry, presents his experience and the reasons for choosing Skill Software. Managing project developments and processes, as well as FMEA and monitoring plans, he shares the results he has encountered on the significant impact of such FMEA software, notably in terms of compliance, automated communication, reactivity to failures and adjustment of resources for optimum quality.
Can you introduce yourself and the challenges you face in FMEA?
"We work in forging and hot stamping for the automotive industry. We make so-called safety parts. As Quality Correspondent, I act as an interface between the customer, management and the workshops, where I manage complaints. Before that, I worked in risk analysis. I was in charge of FMEAs and monitoring plans, as well as control documents within the Quality department. So it was from there that I started working with Skill and developing what we needed for my company and our business sector. Compliance with IATF and ISO standards, as well as meeting customer requirements, car manufacturers, are major challenges in our sector."
In the automotive industry, compliance with IATF 16949 and ISO 9001 standards is fundamental to guaranteeing product quality and reliability. The IATF 16949 standard, drawn up by the International Automotive Task Force, is based on ISO 9001 and incorporates requirements specific to the automotive sector. It aims to improve product quality, prevent defects and reduce variation and scrap in the production chain. IATF 16949 certification is often a prerequisite for being considered a reliable supplier by major automakers. It also provides access to new markets and enhances a company's competitiveness.
In this context, investment in software dedicated to the creation and management of FMEAs is essential to structure, standardize and standardize risk studies within the company, thus improving the efficiency and consistency of deliverables intended for customers. It also facilitates communication between different teams (R&D, quality, production, maintenance) by centralizing data and ensuring rigorous follow-up of action plans.
What's more, FMEA software saves significant amounts of time - up to 50% - in carrying out studies, and delivers a rapid return on investment. By helping to identify and analyze potential failures right from the design phase, it enables appropriate corrective or preventive actions to be planned, and product quality to be improved before the product is put on the market.
Finally, the use of FMEA software is a major asset during IATF and ISO certification audits, as it guarantees the traceability and justification of all modifications made, thus reducing audit-related stress and improving the company's image in the eyes of increasingly demanding customers.
What were your initial motivations for choosing Skill FMEA Pro as your FMEA software?
"We have evolved in response to our own requirements and the non-conformities encountered during customer audits and audits by IATF certification bodies such as the TUV (Technischer Überwachungsverein). Customers, our company and the TUV had different expectations, so we had to find a system that met everyone's requirements. Before FMEA grids were harmonized, each manufacturer had different grids, calculation methods and RPIs (Risk Priority Indices). Skill Software offered a solution that made it possible to switch from one customer to another at the click of a button, which was a decisive factor in our choice."
For an automotive supplier, choosing an FMEA software publisher capable of developing a solution that meets all industry standards has a number of advantages. In fact, it enables all types of FMEA to be managed in a single tool, whatever the customer's sectoral constraints.
It was not uncommon for major car manufacturers to impose different standards and methods for carrying out FMEAs. Flexible software that can easily respond to and switch from one standard to another (AIAG, VDA, IATF, etc.) guarantees compliance with each customer's requirements, without having to multiply the tools.
Unified software to manage Product, Process and DRBFM FMEAs, monitoring plans, flow diagrams, etc. ensures consistency and traceability of all data, avoiding the risk of errors and loss of information associated with the use of multiple, compartmentalized tools. By centralizing all FMEA studies in a single software package, teams gain in efficiency and productivity, and no longer need to juggle between different tools or complex Excel files. A solution that facilitates and ensures information sharing and traceability of modifications, essential points during certification audits.
What's more, centralized FMEA software leads to improved collaboration between the various stakeholders (engineers, quality, production, etc.) thanks to simplified access to data and a fluid user interface. This favors communication and team decision-making, major benefits for the success of complex projects in the automotive industry.
Can you tell us about the benefits and results you've seen from using Skill Software's solution?
"Initially focused on monitoring plans, our use of Skill Software's solution has extended to risk analysis and various specific developments. For example, the Skill Infra Convert feature, developed at our request, automates the integration of features directly from drawings, considerably reducing input time and human error.
Another notable advance was the introduction of Skill Production Reader, which facilitates reverse FMEA without the need for physical meetings. Automatic failure notification by production teams saves us around 60 hours per project, and allows operators to be more involved in the quality management process, reinforcing their commitment and understanding of customer requirements.
This approach has also enabled us to re-evaluate and adjust our control processes, avoiding over-quality and targeting controls on the really problematic areas. In this way, we have harmonized our understanding of field realities and customer imperatives, improving our efficiency and compliance during audits."
Modern FMEA software enables seamless integration with monitoring plans. When a characteristic is modified in the FMEA, the associated surveillance plan is automatically updated, avoiding manual transcription errors and ensuring total consistency between the two documents. This bi-directional synchronization considerably speeds up processes and facilitates communication between the different teams involved.
Thanks to features such as "Reverse FMEA", production operators can directly notify any faults encountered on their workstations. These notifications are automatically integrated into the FMEA software, enabling the quality and engineering teams to react quickly without having to organize time-consuming meetings (after the failure has been verified by a field team, and the frequency of occurrence and means of detection have been rated). This fluid, real-time communication optimizes risk management and encourages the involvement of all players.
By centralizing all information relating to potential failures, controls and corrective actions, FMEA software provides a precise overview of actual risks. This enables resources to be adjusted accordingly, by tightening controls on critical points and streamlining redundant or unnecessary processes. In this way, companies avoid both costly over-quality and damaging under-quality, optimizing their efficiency and profitability.
Finally, traceability of changes made to FMEAs and monitoring plans is essential to meet the requirements of certification audits. Dedicated software ensures rigorous tracking of all changes, with electronic justification and approval. What's more, standardized processes and centralized data greatly facilitate the preparation and conduct of audits, reducing stress and the risk of non-compliance.
Which elements of the Skill FMEA Pro solution and Skill Software support do you find most beneficial?
"Skill Software's strengths include their attentive listening, availability, transparency and tenacity in finding suitable technical solutions. They take care of their customers, which is essential for the successful integration of an FMEA solution."
In the field of FMEA software, attentive listening and proximity to customers are essential for an in-depth understanding of their specific needs and the technical challenges they face. A customer relationship based on active listening enables the software publisher to quickly grasp customers' particular requirements, adapt to market developments and anticipate future needs. This proactive approach favors the customization of software solutions, ensuring that they precisely meet the expectations and constraints of each customer.
To achieve this, the editor's availability and responsiveness are key elements in maintaining a relationship of trust with its customers. Fast, efficient technical support is decisive in resolving any problems that may arise during the implementation and day-to-day use of FMEA solutions. This responsiveness minimizes service interruptions and ensures operational continuity, which is particularly important in industries where downtime can have significant consequences for production and product quality.
Transparency in customer interactions is essential to build trust and cooperation. FMEA software publishers need to communicate clearly and honestly about their products' capabilities and limitations, as well as development timescales and processes. This transparency enables customers to make informed decisions and effectively plan their activities in line with anticipated software developments. Open communication also helps to manage expectations and prevent misunderstandings.
Last but not least, an FMEA software vendor committed to ongoing development and innovation is better equipped to provide solutions to complex technical issues. By investing in R&D and collaborating closely with their customers, publishers can identify new opportunities for improvement and develop advanced functionalities that meet emerging needs. The adaptability and customizability of software solutions are crucial to meeting diverse customer needs. Each customer may have different processes, regulatory requirements and quality standards, requiring specific adjustments to the FMEA software. A software vendor able to provide modular and flexible solutions, as well as customization services, can better meet each customer's unique requirements, thus increasing the software's added value.
In a few words, how would you describe Skill Software and their Skill FMEA Pro solution?
"Skill Software is a team that listens to its customers, giving the will to improve and always respond positively to benefit its customers."
