About the project
An urgent request was issued to deliver a process Failure Mode and Effects Analysis (pFMEA) for the newest hardware release. The project came with tight deadlines and significant design uncertainties, requiring close coordination between design, assembly, and safety teams.
The client continuously improves their machines by introducing newer versions of existing systems. In this case, a key device was redesigned, resulting in a completely new layout and a cascade of changes to tools, parts, and processes. To ensure production readiness and risk control, a thorough and structured pFMEA was essential, even under time pressure.
The task
WEB was asked to support the creation and facilitation of the pFMEA process by:
- Supporting the installation pFMEA.
- Leading the alignment and safety checks pFMEA.
How we worked
WEB’s structured approach allowed the team to manage uncertainty while maintaining progress and quality.
- Investigation – Collected all available technical data, identified missing information, and mapped potential risks.
- Documentation – Created a step-by-step overview for each action and process in scope.
- Workshops – Organized cross-functional sessions to review each process step and brainstorm possible failure modes.
- Ranking sessions – Facilitated discussions with key stakeholders to evaluate risks and define mitigation actions.
The solution
The pFMEA was delivered on time, providing a clear and actionable overview of potential risks. Collaborative sessions ensured alignment among all stakeholders, and each risk was carefully ranked and mitigated.
All major issues have now been either resolved or are being actively managed based on the pFMEA outcomes. The results are also serving as input for follow-up documentation and the creation of detailed work instructions, ensuring a more reliable and transparent process moving forward.
