Overview and Benefits

DataLyzer FMEA software

 

For manufacturers worldwide, FMEA has become synonymous with continuous improvement programs. Process Flows, FMEA, control plan and SPC have a logical connection. The FMEA process ensures that products, processes or detection techniques are constantly improved.

Continuous feedback is provided from SPC results on the shop floor to engineers responsible for the FMEA process. DataLyzer FMEA software is a module where all data is integrated with the DataLyzer database making it possible to exchange SPC and Process Flow/FMEA/Control Plan information between employees, and ensuring that FMEAs and Control Plans are truly living documents.

DataLyzer® FMEA  is one of the modules in the DataLyzer software suite. The program closely follows the methodology defined in IATF 16949 (VDA AIAG) and RM13004. DataLyzer FMEA can operate as a stand-alone module or link to DataLyzer Spectrum SPC software.

DataLyzer offers a transition training to explain the details of this new manual and how this can be implemented by using DataLyzer FMEA. Please contact your Account Manager or sales@datalyzer.com for more information.

DataLyzer fully supports the new harmonized AIAG-VDA FMEA system. Users can switch without any problem between different methods and templates.

Some of the changes in the AIAG VDA FMEA:

  • RPN has disappeared and is replaced by Action Priority. See how this is implemented in DataLyzer FMEA in this video.
  • A 7-step process needs to be implemented
  • The criteria tables have changed. In addition to the change you can add extra columns in DataLyzer FMEA for further clarification.
  • Some columns in old FMEA will be changed, split or merged.

 

For automotive suppliers this means a big change if they are not using FMEA software yet which is capable of the new functionality. For new FMEAs the new method will be audited. If you want to know more about the changes you can read this article.

For Food industry our FMEA software can be used to comply to HACCP  requirements.

In the Aerospace industry it is used to comply to RM13004. Our FMEA software is also fully compliant with ITAR/EAR regulations. FMEA documents are technical documents which fall under ITAR/EAR regulation.

The software runs in many languages (English, Spanish, French, German, Portuguese, Hungarian, Danish, Dutch, Chinese, Turkish and more are added) and it is possible to automatically translate documents to any other language – even the content -.  This makes DataLyzer FMEA extremely suitable for international customers who want to exchange information between plants.

 

Typical results of the implementation of DataLyzer FMEA software:

  • Significant reduction of engineering time to prepare the Process Flow/FMEA/Control Plan.
  • Proper registration of engineering knowledge due to the structured setup of standard and specific FMEAs and Control Plans
  • Efficient action follow-up.
  • Fewer problems during customer or system audit.
  • More time on process improvement, rather than on running the FMEA system.

Features

Customize to your Industry

FMEA criteria and classification symbols can be customized, even per group of documents. Multiple sets of standard texts for FMEA and Control Plan can be used. This set up guarantees consistency and saves time when completing FMEAs. Alarm levels for RPN or Action priority or severity are also defined. Several additional setup preferences support exact configuration to your needs.

Granular Authorization

The FMEA software supports users, roles, and permission schemes. Obtain complete control access to specific documents through users, user groups, documents or document groups, making DataLyzer FMEA best-suited for use even in a multi-plant environment. User management can be linked to Active Directory.

Create and Generate Process Flows

Process flow must be created before creating the process FMEA. The software supports the development of a primary and secondary flow and offers standard symbols. Changes in the process flow are automatically updated in the process FMEA and vice-versa.

Reference FMEA and special filter columns

FMEAs can be maintained a lot easier if you work with reference FMEAs. The Reference FMEAs can be made on multiple levels. Changes in Reference FMEAs will be updated automatically in all FMEAs  using these reference FMEAs.

In some situations adding filter columns will help to facilitate the development of FMEAs.  DataLyzer FMEA offers the  option to add multiple columns for example for different producttypes.

IATF 16949 / RM13004 Validation

Forget about formatting and just key in data. Validation rules can be applied to ensure relevant regulations and the prescribed IATF 16949, RM13004 or other formats are followed, leaving no room for error. This is specifically important for auditors. Linkage of process flow, FMEA and Control Plan prevents conflicts between the 3 documents. DataLyzer FMEA system is adopted to comply with new harmonized AIAG VDA FMEA methodology. You can seamlessly switch between multiple formats, no conversion is required.

Root cause Analysis

Ascertain the root cause from “5 Why” problem-solving approach and the Ishikawa (Fishbone) analysis stored within the FMEA.

Action priority

The action priority method according to the new harmonized AIAG VDA FMEA method is implemented. You can switch between RPN and Action priority or show them both. Rows can be filtered on Action Priority and/or RPN. See this video.

Open Actions

Report incomplete actions in any FMEA in an open action list and directly access the FMEA. Receive Email notificationd in case actions are almost due.

Agile Control Plan interconnecting FMEA, SPC and drawing or 3D Model

Import characteristics directly from ballooning software like for example Elias, SolidWorks, Discus etc. With the integration between ballooning software and DataLyzer you can fill out the FMEA and Control Plan directly from a PDF, DWG, DXF, IGES, Catia, NX Models etc etc. Create the SPC control charts directly from the Control Plan to minimize redundant data entry. Integration with PLM systems like Teamcenter will be available soon.

Flexibility & User-Specific requirements

Diverse customer requirements demand flexible software to assist users with the FMEA/Control Plan process. Adding columns as per customer requirements or adding a classification column for Pass Through Characteristics (PTC) is easy. Six specific user defined fields per document allows customization as per your needs. Translate the FMEA or Control Plan contents while printing, enabling you to create the CP in the customer-specified language and print the Control Plan in another language for shop floor operators.

Manage your FMEAs and Reports

Print Pareto reports of the top X RPN numbers from a document or group of documents, analyze documents  or print reports. Set priorities and manage progress of the continuous improvement process. Keep FMEA documents alive by the feedback from DataLyzer SPC to the FMEA process.

Training

DataLyzer FMEA software is so intuitive that not much training time is required. In addition to the manual, 14 tutorial videos explain how to setup FMEA using DataLyzer FMEA. To watch the tutorials, click on the View Tutorial link. If desired, we can provide additional User Training for DataLyzer FMEA.

For more information please download the brochure.

Video Tour

DataLyzer FMEA Software Guided Tour

Over 14 videos support the implementation. Below you see 2 of them.

The movie below gives you an introduction to Advanced Planning Quality Process and how DataLyzer’s FMEA software fits in your APQP process.


Understanding FMEA Structure

The movie below gives you a clear understanding of the FMEA document structure and the relationships.

Whitepapers

Whitepapers

Introduction to Risk Analysis

In the concept version of ISO 9000:2015 risk analysis will be a requirement. This white paper describes an introduction to risk analysis and FMEA, the history of FMEA, how to get started with FMEA and the layout for IATF 16949.

Managing FMEA’s

What is required to make your FMEA program a success? What do you need to prepare before starting with FMEAs and what do you need to do per individual FMEA.

FMEA Classification

How are is priority for improvement established and how are classification symbols and special characteristics used in FMEA? Different methods will be discussed for prioritizing: Risk Priority Matrix, RPN, Action Priority, Classification Symbols.

Is Excel the right tool for FMEA?

It seems at first but there are so many specific requirements which are very complicated to implement in Excel, that Excel is hardly the right tool.

FMEA and HACCP: A comparison

In industries, FMEA is used. In Food industry HACCP is used. What are the similarities and differences and what would be the advantages for the Food industries to apply FMEA.

FMEA and Cost Effectiveness

What problems do we fix, how much do they cost us? What are the current costs of customer returns? Does the FMEA affect the bottom line or the top line? How can FMEA generate new business?

Capturing Process Knowledge using Standard FMEAs

How can knowledge be stored in FMEAs and re-used with new product and process development.

AIAG VDA FMEA

The new FMEA manual has restructured the FMEA process.  In this article we will summarize the major changes.


DataLyzer FMEA in different industries

This whitepaper shows how DataLyzer FMEA can be used throughout numerous different industries. It also highlights several features that have been added to improve the functionality of DataLyzer FMEA.

Why not Excel?

Why Choose DataLyzer FMEA over Excel?

  • The  layout of the FMEA is very strict and creating the prescribed format in Excel is time-consuming. DataLyzer FMEA not only automatically adjusts the layout while typing, but also ensures adherence to the prescribed structure. For more details, click on view tutorial below.
  • Since Excel doesn’t support the underlying FMEA structure and only allows you to copy or move rows, copying or moving parts of the structure is impossible.
  • If you want to analyze FMEAs by sorting, grouping or filtering that is not possible in Excel and certainly not across multiple FMEAs. In DataLyzer FMEA that is possible.
  • In Excel, FMEAs and CPs must be issued and older versions must be maintained. Moreover, issuing and creating new documents requires immense effort and stringent procedures. DataLyzer’s validation rules ensure that the FMEA is correct even before it is released.
  • Saves time by using reference FMEAs for standard processes and adopting these in specific FMEAs.
  • Open actions in FMEAs are managed in an action list, which can be printed by a manager/ engineer and sorted by due date. It is also possible to send reminder mails if an action is almost due. That is not possible in Excel.
  • CPs are standardized and can be translated automatically before printing.
  • Changing the language of the FMEA is simple and enables you to view the information in your local language.
  • Automatically importing the characteristics into the FMEA or CP from drawings using ballooning software saves time and effort.
  • Using Action Priority requires programming in Excel to implement. This means you need to implement macros in every FMEA Excel sheet
  • FMEA might require extended user configuration and authorization and documetn control which is not supported in Excel.
  • The new 6 step process used in automotive results in approx 30 columns instead of 20 and requires a relation between FMEAs. This is very hard to implement in Excel. In the new FMEA manual it is recommended to switch to dedicated FMEA software.

 

See this whitepaper for more details. To facilitate the start-up of DataLyzer FMEA, the Excel FMEAs can be imported.

Ballooning

Integrated APQP: 3D Model/2D Drawing – Ballooning – FMEA – Control Plan – CMM – SPC- FAIR

Early in the design process product characteristics and its classification are established and specifications are defined. These characteristics are forwarded in every step of the APQP process and are measured, analyzed, controlled and reported in First Article Inspection Report (FAIR), PPAP and SPC reports.

DataLyzer together with DISCUS is the only combination able to offer an integrated solution from 3D model or drawing for the full APQP process to SPC and FAIR reporting.

  • Adding of balloons to a 3D model or 2D drawing makes the characteristics’ list accessible.
  • DataLyzer offers a flexible tool to import characteristics from any ballooning software
  • This list can be imported during the FMEA and Control Planning process.
  • Map the characteristics to the appropriate machine/device/jig/tool field. Also add other fields such as (a fixed subgroup size, OCAP) that are not available in the ballooned data.
  • Perform the required measurement systems analysis
  • Export the characteristics to the DataLyzer SPC software
  • Import data from CMM and add data from any other source including visual inspection
  • Report the data in FAIR or SPC reports  or COA’s.

Contact us to check why leading companies in aerospace, automotive and medical devices industry are selecting the DataLyzer solution.

Read this whitepaper for further information.

Whitepapers

Introduction to Risk Analysis

In the concept version of ISO 9000:2015 risk analysis will be a requirement. This white paper describes an introduction to risk analysis and FMEA, the history of FMEA, how to get started with FMEA and the layout for IATF 16949.

Managing FMEA’s

What is required to make your FMEA program a success? What do you need to prepare before starting with FMEAs and what do you need to do per individual FMEA.

FMEA Classification

How are is priority for improvement established and how are classification symbols and special characteristics used in FMEA? Different methods will be discussed for prioritizing: Risk Priority Matrix, RPN, Action Priority, Classification Symbols.

Is Excel the right tool for FMEA?

It seems at first but there are so many specific requirements which are very complicated to implement in Excel, that Excel is hardly the right tool.

FMEA and HACCP: A comparison

In industries, FMEA is used. In Food industry HACCP is used. What are the similarities and differences and what would be the advantages for the Food industries to apply FMEA.

FMEA and Cost Effectiveness

What problems do we fix, how much do they cost us? What are the current costs of customer returns? Does the FMEA affect the bottom line or the top line? How can FMEA generate new business?

Capturing Process Knowledge using Standard FMEAs

How can knowledge be stored in FMEAs and re-used with new product and process development.

AIAG VDA FMEA

The new FMEA manual has restructured the FMEA process.  In this article we will summarize the major changes.


DataLyzer FMEA in different industries

This whitepaper shows how DataLyzer FMEA can be used throughout numerous different industries. It also highlights several features that have been added to improve the functionality of DataLyzer FMEA.

Why not Excel?

Why Choose DataLyzer FMEA over Excel?

  • The  layout of the FMEA is very strict and creating the prescribed format in Excel is time-consuming. DataLyzer FMEA not only automatically adjusts the layout while typing, but also ensures adherence to the prescribed structure. For more details, click on view tutorial below.
  • Since Excel doesn’t support the underlying FMEA structure and only allows you to copy or move rows, copying or moving parts of the structure is impossible.
  • If you want to analyze FMEAs by sorting, grouping or filtering that is not possible in Excel and certainly not across multiple FMEAs. In DataLyzer FMEA that is possible.
  • In Excel, FMEAs and CPs must be issued and older versions must be maintained. Moreover, issuing and creating new documents requires immense effort and stringent procedures. DataLyzer’s validation rules ensure that the FMEA is correct even before it is released.
  • Saves time by using reference FMEAs for standard processes and adopting these in specific FMEAs.
  • Open actions in FMEAs are managed in an action list, which can be printed by a manager/ engineer and sorted by due date. It is also possible to send reminder mails if an action is almost due. That is not possible in Excel.
  • CPs are standardized and can be translated automatically before printing.
  • Changing the language of the FMEA is simple and enables you to view the information in your local language.
  • Automatically importing the characteristics into the FMEA or CP from drawings using ballooning software saves time and effort.
  • Using Action Priority requires programming in Excel to implement. This means you need to implement macros in every FMEA Excel sheet
  • FMEA might require extended user configuration and authorization and documetn control which is not supported in Excel.
  • The new 6 step process used in automotive results in approx 30 columns instead of 20 and requires a relation between FMEAs. This is very hard to implement in Excel. In the new FMEA manual it is recommended to switch to dedicated FMEA software.

 

See this whitepaper for more details. To facilitate the start-up of DataLyzer FMEA, the Excel FMEAs can be imported.

Ballooning

Integrated APQP: 3D Model/2D Drawing – Ballooning – FMEA – Control Plan – CMM – SPC- FAIR

Early in the design process product characteristics and its classification are established and specifications are defined. These characteristics are forwarded in every step of the APQP process and are measured, analyzed, controlled and reported in First Article Inspection Report (FAIR), PPAP and SPC reports.

DataLyzer together with DISCUS is the only combination able to offer an integrated solution from 3D model or drawing for the full APQP process to SPC and FAIR reporting.

  • Adding of balloons to a 3D model or 2D drawing makes the characteristics’ list accessible.
  • DataLyzer offers a flexible tool to import characteristics from any ballooning software
  • This list can be imported during the FMEA and Control Planning process.
  • Map the characteristics to the appropriate machine/device/jig/tool field. Also add other fields such as (a fixed subgroup size, OCAP) that are not available in the ballooned data.
  • Perform the required measurement systems analysis
  • Export the characteristics to the DataLyzer SPC software
  • Import data from CMM and add data from any other source including visual inspection
  • Report the data in FAIR or SPC reports  or COA’s.

Contact us to check why leading companies in aerospace, automotive and medical devices industry are selecting the DataLyzer solution.

Read this whitepaper for further information.