For the first time as a supplier, WEB was tasked with executing a complete Process Failure Mode and Effects Analysis (pFMEA) for a specific module and its full installation and de-installation process.

The assignment came with significant challenges: limited available data, no existing design as a baseline, scattered stakeholder input, and a strict deadline. Despite these constraints, WEB was determined to deliver a structured, risk-based approach that would ensure process robustness from the start.

The task

WEB was responsible for preparing and facilitating the entire pFMEA, from defining process steps to identifying, ranking, and mitigating potential risks, while coordinating input across multiple stakeholder groups.

Key challenges included:

• Incomplete process steps for the module installation.
• Absence of an existing design, leaving no prior risk foundation.
• Need to align with multiple teams to ensure engagement during brainstorming and ranking sessions.

How we worked

WEB applied a structured and data-driven methodology to handle uncertainty while maintaining project pace and quality.

1. Investigation – Collected all available technical data, including module drawings, draft installation instructions, tooling requirements, and handling constraints.
2. Documentation – Structured the findings into a detailed step-by-step description of the entire install/deinstall process, creating a technical slide deck for cross-functional review.
3. Workshops – Organized collaborative workshops to review each process step, brainstorm potential failure modes, and define their causes and effects.
4. Ranking sessions – Facilitated structured ranking sessions with all stakeholders to evaluate failure modes based on Severity, Occurrence, and Detection criteria, ensuring prioritized and actionable mitigations.

The solution

Despite being a first-time effort with limited information and a tight timeline, the pFMEA was delivered on schedule. The structured approach enabled:

• A comprehensive risk overview used to refine process documentation and tooling details.
• Clear alignment between installation instructions and identified risks.
• Early detection of potential failure modes, allowing proactive mitigation and preventing downtime.
• A transparent, data-driven risk assessment framework that accelerated decision-making.

All mitigation actions have since been implemented, and the risk-based improvements are now fully integrated into the updated procedures, ensuring a more robust and reliable process for future module installations.

The post From pressure to precision: Achieving first-time right with pFMEA appeared first on One WEB.

With the introduction of a new system at the client site, new alignment sequences were required for the device installation. Meeting the planned installation time for this completely new setup posed a major challenge. The project involved:

• Brand-new hardware and tooling.
• First-time execution of the alignment sequence at the customer site.
• Limited operator experience with the new procedure.

The task

WEB was asked to ensure a smooth and efficient installation process by supporting the development, validation, and first execution of the new alignment sequence, aiming for a “first-time-right” result within the expected installation schedule.

How we worked

To achieve this, WEB collaborated closely with the client’s engineering and production teams, ensuring clarity, structure, and speed in every phase.

1. Process definition – Worked together with the client’s engineering team to redefine the Method of Procedure and optimize the automated alignment database process.
2. Early validation – Involved factory production engineers early in the review process to validate procedures and ensure feasibility.
3. On-site support – Provided close support during prototype execution and ensured rapid resolution of comments and issues during the proto phase.

The solution

The sequence execution during machine installation was completed successfully and received no comments. The optimized approach led to a significant reduction in installation time, resulting in measurable efficiency gains for the client.

Lessons learned from this successful implementation are now being applied across the broader automated process, helping to further standardize and accelerate future system installations.

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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.

1. Investigation – Collected all available technical data, identified missing information, and mapped potential risks.
2. Documentation – Created a step-by-step overview for each action and process in scope.
3. Workshops – Organized cross-functional sessions to review each process step and brainstorm possible failure modes.
4. 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.

The post Delivering a critical pFMEA for a new machine under pressure appeared first on One WEB.

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.

Solution

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.

The post Identifying Risks with FMEA for Safe Work Instructions appeared first on One WEB.