Perform Failure Mode & Effects Analysis (FMEA) Inspection using eAuditor
Failure Mode & Effects Analysis (FMEA) is a systematic, proactive method used to identify potential failure modes in products, processes, or systems, assess their impacts, and prioritize corrective actions to reduce risks.
Performing Failure Mode & Effects Analysis (FMEA) Inspection using eAuditor ensures a structured evaluation of potential failure modes, their causes, and effects in products, processes, or systems, helping organizations proactively identify risks, prioritize corrective actions, and improve overall reliability.
By using eAuditor, the FMEA process becomes more streamlined through digital checklists, automated risk scoring, photo documentation, and real-time corrective action tracking.
Purpose of FMEA Inspection using eAuditor
The primary objectives of conducting an FMEA inspection using eAuditor are to:
- Identify potential failure modes in processes, products, or systems
- Assess the severity, likelihood, and detection capability of each failure
- Prioritize risks based on the Risk Priority Number (RPN)
- Assign and monitor corrective actions for high-risk items
- Ensure product quality, process reliability, and regulatory compliance
- Maintain digital records for audit purposes and continuous improvement
Step-by-Step Process for Performing FMEA Inspection using eAuditor
Prepare the eAuditor FMEA Inspection Template
Set up the inspection checklist by:
- Logging into your eAuditor account
- Downloading or creating an FMEA Checklist Template
- Defining key sections, such as:
- Process or Product Information
- Failure Mode Identification
- Failure Effects and Severity
- Detection Methods and Detection Rating
- Failure Causes and Occurrence Rating
- Risk Priority Number (RPN) Calculation
- Corrective Actions
Process or Product Information
Document basic information to standardize the inspection:
- Process or product name
- Department or system name
- Inspection date and time
- Inspector’s name
Enter these details directly into the eAuditor digital form.
Identify Failure Modes
List all potential ways the product, system, or process could fail under normal conditions.
Example failure modes include:
- Component malfunction
- Incorrect assembly
- Process deviation
- Material defects
Use eAuditor to categorize each failure mode by section or process step.
Failure Effects and Severity Assessment
Describe the consequences of each failure mode on the product or process performance.
Assign a Severity Rating (1-10) based on the following:
- 1 = No noticeable effect
- 10 = Catastrophic effect on safety or performance
Log the severity rating directly into eAuditor for automatic risk scoring.
Failure Causes and Occurrence Rating
Identify the root cause of each failure mode (e.g., human error, material defect, machine failure).
Assign an Occurrence Rating (1-10) based on the likelihood of the failure happening:
- 1 = Extremely unlikely
- 10 = Highly likely
Attach photos or comments to provide further evidence or explanation.
Detection Methods and Detection Rating
List current methods used to detect each failure mode, such as:
- Visual inspections
- Quality control checks
- Automated sensors
Assign a Detection Rating (1-10) based on the ability to detect the failure:
- 1 = Certain detection
- 10 = No detection
Risk Priority Number (RPN) Calculation
eAuditor automatically calculates the Risk Priority Number (RPN) using the formula:
RPN = Severity × Occurrence × Detection
Higher RPN values indicate higher-risk failure modes that need immediate corrective action.
Assign Corrective Actions
For failure modes with high RPN scores:
- Recommend corrective actions to eliminate or reduce the risk
- Assign responsible personnel
- Set priority levels and due dates
- Attach photos, notes, or supporting documents
Track corrective actions directly within eAuditor to ensure completion.
Sign-Off and Report Submission
After completing the inspection:
- Review the FMEA checklist
- Add final comments
- Sign off with a digital signature
eAuditor automatically generates a detailed PDF report and stores it securely in the cloud for future reference and audit purposes.
Conclusion
Performing Failure Mode & Effects Analysis (FMEA) Inspection using eAuditor helps organizations proactively manage risks, improve product reliability, and maintain operational efficiency. The digital platform simplifies the process by providing automated risk calculations, corrective action tracking, and cloud-based report storage, ensuring a more effective and transparent risk management system.