Identifying risks to deliver proper and safe work instructions using FMEA processes

In a high-tech system project, we used the FMEA process to identify and address risks early in the design stage. Collaborating with designers and stakeholders, we assessed assembly steps, created detailed illustrations, and managed critical risks. This ensured safe work instructions and influenced future design improvements.

About the project

For a high-tech system, we got involved early in the design stage. During this project, we used the FMEA process (Failure Modes and Effects Analysis), a common tool in industrial engineering. FMEA is utilized when designers develop the initial concept, even before any hardware is in place. By working with designers, we assessed how the design is assembled, determined where each part belongs, and evaluated each step with the help of illustrations.

The task

The goal of this project was to identify risks and failure modes as early as possible. Once identified, these risks were addressed and adjusted within the design and processes. Our analysis helped answer critical questions such as: Can we assemble the part? Can the operator reach it? Does the design need to be reworked?

We considered various scenarios. For example, some parts were located under the floor, accessible by lifting a tile, exposing a gap below. A key risk identified was: what happens if a screw is dropped during installation? We assessed each risk to determine its validity, severity, and frequency. This was done collaboratively with a facilitator and other experts.

How we worked

We organized a brainstorming session with stakeholders, including customer support, industrial engineers, designers, architects, functional designers, and other experts. We presented the parts, their installation process, and provided illustrations and detailed descriptions. This brainstorming session allowed us to evaluate the process, discuss risks, and delegate tasks to the appropriate stakeholders. Being involved in the design and documentation stages, we documented quality procedures thoroughly.


After ranking the risks, we used a ticket system to identify and manage the most critical ones. Each ticket described the problem, its origin, the owner, and the person responsible for solving it. With the help of FMEA, we successfully identified all the risks, managed stakeholder involvement, while ensuring safe and reliable work instructions.