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.

Diagnosing issues in high-tech machine systems requires expertise from multiple disciplines and the right diagnostic tools. One of these tools is the Deterministic Diagnostic Flow (DDF), which helps identify potential failures based on specific system errors. By collaborating with stakeholders across engineering, design and support, we mapped out the possible failure modes of a recurring error and developed a structured approach to solving it.

The task

The objective of this project was to identify all possible failure modes linked to a specific system error. By systematically diagnosing the components, the team aimed to trace the problem back to one root cause. Once identified and fixed, the machine could quickly be brought back into operation. Each DDF was documented, saved and reused whenever the same error occurred in the future, providing a repeatable solution that reduced troubleshooting time.

How we worked

To tackle the problem effectively, we organized a workshop session with stakeholders including customer support teams, industrial engineers and system designers. During this session, we:

• Mapped out all possible causes of the error

• Discussed the likelihood of each potential failure mode

• Identified the actions needed to resolve each scenario

This collaborative approach ensured that the most realistic and effective solutions were prioritized.

The solution

By documenting the failure modes and linking them to clear actions, we created a practical tool that has since proven highly effective. Each time the error occurs, the DDF guides engineers directly toward the root cause.

This approach delivered:

• Faster resolution of system issues

• Reduced downtime and production loss

• A reusable diagnostic framework for future troubleshooting

The DDF has become a reliable method for troubleshooting, ensuring that complex machines can return to full operation in less time, with greater accuracy.

The post Using Deterministic Diagnostic Flow (DDF) to Solve Complex System Errors appeared first on One WEB.

One of our clients needed to boost the throughput of a machine, which meant redesigning a specific module. Our mission was to improve the assembly process of a complex mechatronic module, specifically for the cable slab.

The issue

Unfortunately, the new assembly resulted in issues because of the new electric power cables and cooling hoses that were required. This meant we had to optimize the production process of the cable slabs. On top of that, the customer didn’t have the capacity to manage the redesign and lacked a step-by-step procedure.

Solution

With a team of WEB project engineers, we divided the entire assembly process. We investigated if we could work with sub-assemblies so that we could reduce the amount of time needed to create the entire module. Our team of WEB project engineers stepped in and broke down the entire assembly process. We looked into using sub-assemblies to cut down the time needed to create the whole module.

To create the instructions, we used 3D models and made regular visits to the factory to ensure we had the correct information. These instructions were then reviewed by factory engineers and operators. We took all their feedback into account, which led to the release of a new and improved procedure for the customer.

To make a solid product, you need the right procedures in place. Our team helped ensure that everyone in the department, from low to high complexity, was able to follow the procedures that we developed. With our help, we were able to fine-tune the process and optimize the production process.

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