Identify systematic problems and find structured solutions
Error and Fault Management
Failure and Error Management is a structured approach used to identify, analyze, and prevent failures and errors in products, processes, and systems. It focuses on understanding the root causes of failures and implementing corrective actions to improve process reliability and product quality. It is a key part of quality management, risk management, and continuous improvement in engineering and manufacturing environments.
Why is Failure and Error Management Important?
Effective failure and error management helps organizations reduce risks and improve performance.
Key benefits include:
✓ Reduction of process failures and defects
✓ Improved product reliability and quality
✓ Faster identification of root causes of errors
✓ Improved risk analysis and risk mitigation
✓ Support for continuous improvement and problem solving
When Should Failure and Error Management Be Used?
Failure and Error Management is applied whenever organizations need to identify and control risks in processes or products.
Typical situations include:
» Failure analysis in production or field issues
» Quality problem solving and defect reduction
» Root cause analysis of process errors
» Risk management in product development
» Corrective and preventive actions
What Types of Failure and Error Management are used?
Different types of Failure and Error Management tools are:
• Failure Mode and Effects Analysis (FMEA)
A structured method for risk analysis and identification of potential failures in design and processes.
• Root Cause Analysis (RCA)
Used to identify the root causes of failures and errors using methods such as 5 Whys and Fishbone Diagram.
• Corrective and Preventive Actions (CAPA)
Focuses on eliminating causes of detected problems and preventing recurrence.
What are the Common Mistakes in Failure and Error Management ?
Organizations often make mistakes such as:
♦ Treating symptoms instead of identifying root causes of failures
♦ Lack of structured failure analysis methods
♦ Poor documentation of errors and corrective actions
♦ Limited cross-functional involvement
♦ Failure to implement preventive measures
What 7SIGMA can do to help your Organisation?
7SIGMA supports organizations in implementing Failure and Error Management through:
√ Failure analysis and root cause analysis support
√ Implementation of FMEA and risk management methods
√ Support for CAPA and problem-solving processes
√ Workshops on quality problem solving and defect analysis
√ Development of structured error management systems
What Standards and References that are Existing for Failure and Error Management?
The most Common standards are:
¤ ISO 9001 Quality Management Systems
¤ IATF 16949 automotive quality standards
¤ FMEA (AIAG & VDA methodology)
Where I can find more Information?
A Detailed Method description you can find here.