Failure Mode Effect Analysis (FEA) Services
Structured FMEA, DFMEA and PFMEA support for machinery, automation systems, production equipment.
We lead collaborative workshops with your key stakeholders to identify potential failure modes early, understand their effects and agree practical corrective actions before issues are built into the project.
Collaborative FMEA Workshops
Neuguard leads Failure Mode and Effects Analysis workshops with the client’s key stakeholders, bringing together the people who understand the design, process, operation, maintenance, quality and safety requirements of the equipment.
FMEA is most effective when completed at the beginning of a project, before the design is fixed, equipment is built or key decisions have already been made. Involving us early allows potential failure modes to be identified while there is still time to influence the design, reduce risk and avoid costly late-stage changes.
During the FMEA process, we facilitate the discussion, challenge assumptions, document potential failure modes and work with the project team to agree proportionate corrective actions.
DFMEA and PFMEA Support
We can support both Design Failure Mode and Effects Analysis and Process Failure Mode and Effects Analysis, depending on the stage and nature of the project.
DFMEA is used to review the design of machinery, assemblies, control systems, tooling or safety-related upgrades. It helps identify how the design could fail, what effect that failure could have, and what design changes or additional controls may be required.
PFMEA is used to review manufacturing, assembly, installation, maintenance or production processes. It helps identify how a process could fail, what the consequences may be for safety, quality, reliability or production, and what process controls or corrective actions are required.
Identifying Failure Modes Early
FMEA is a structured method used to identify how machinery, components, control systems or processes could fail, what the effects of those failures could be, and whether the existing design or control measures are adequate.
Our role is to lead the process with your engineering, production, maintenance, quality, safety and project stakeholders so that the assessment reflects real operational knowledge rather than being completed as a desktop exercise.
We can support FMEA activities for new machinery, automation projects, safety upgrades, production processes and corrective actions identified through risk assessments, PUWER assessments or CE/UKCA compliance reviews.
From Failure Modes to Practical Solutions
The purpose of an FMEA is not simply to create a spreadsheet. The value comes from identifying credible failure modes early and agreeing practical solutions before they become expensive, difficult or disruptive to correct.
Where failure modes are identified, we help the team define suitable actions such as design changes, component upgrades, additional monitoring, improved guarding, revised safety functions, control system changes, pneumatic or hydraulic improvements, maintenance changes, inspection requirements and process controls.
Our machinery safety and compliance background allows us to connect the FMEA process with wider project requirements, including PUWER, CE/UKCA conformity, EN ISO 12100 risk assessment, EN ISO 13849-1 safety function design and EN 60204-1 electrical safety considerations where relevant.
Planning a machinery, automation or production project?
FMEA, DFMEA and PFMEA should be carried out as early as possible in the project lifecycle. If you are developing new equipment, modifying existing machinery, introducing a new process or planning a safety-related upgrade,
Neuguard can lead the FMEA process with your key stakeholders and help turn identified failure modes into practical corrective actions.