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Instructions to download the FMEA template and Excel workbook, will be emailed to you within 10-15 minutes. You are one giant leap closer to great FMEA’s that can help you get up to 5X more products adopted and embraced by your customer(s).

If you do not receive the email from hcooper@i3day.com within 20 minutes, then look in your spam folder, promotions, or updates tab and move the email to your “primary” emails folder (Gmail users). Or,

To get the most from your new FMEA template, watch the short video below, now. Because, I’m not just sending you spreadsheets; this workbook can be your launchpad to getting your products not just accepted, but celebrated by your customer(s) for impeccable reliability, quality and safety.

3 Reasons to Use this FMEA Template
(...instead of the other 4 you already downloaded)

A well done FMEA is an effective and legal ‘due diligence’ document. It shows what has been done to achieve reliability, avoid safety hazards and high warranty repair costs. This FMEA template can also be key to driving maintainability, diagnostics, prognostics, safety and other product improvements. 

But, Wait!   Whether you use this FMEA template to...

While your FMEA Templates are being processed, I have a crucial question to ask you?

You already know FMEA can make or break your career, because it not only drives relevant product  verification and validation testing. FMEA often later becomes a legal document that management and/or the courts, examine to determine whether the development team properly considered and took steps to mitigate critical reliability issues and crucial potential safety hazards, during the design-development phase.

FMEA was the opportunity that made my career "soar with the eagles", but I know too many engineers and product development specialist who were demoted or laid-off, because they did not identify or mitigate critical failure modes during FMEA activities. 

So, here's the crucial question, for you:

How would your team benefit by attending an online workshop, How to Complete Your FMEAs 3X Faster and Not Miss Any Critical Failure Modes?

And because you've requested my FMEA template, I've reserved a 63% Discount for you to attend this online workshop. (but you must respond down below).

What do attendees take away from this workshop?  I share unique tricks (methods & tools), which I now use to complete FMEA activities 3-5 times faster and get better results from the effort. I reveal and give attendees a working knowledge of these methods and tools, to empower them to complete FMEA activities at least 3X faster, without missing any critical failure modes.

Some companies contract me to do FMEA for them or to facilitate their FMEA activity more quickly and effectively. While others are simply wanting to do their own FMEAs faster—in compliance with industry standards and to customer expectations—without missing any critical failure modes.

If that is your goal, here are four FMEA preparation methods and tools I use, to:

Doing so, gives engineers and development specialists the time they need to eliminate or mitigate critical FMs before the next peer review or customer review.

4 Additional Tools

Method/Tool 1: The FBI-Block Diagram

Most often FMEA facilitators or project leads prepare for FMEA team activity by collecting a list of system functions and/or creating an RBD, Reliability Block Diagram, or an FBD, Functional Block Diagram, or what is often called a B-Diagram, Boundary Diagram. Although these models help to describe the system to be analyzed and the components within the system (Items in the FMEA), I have found they are not complete enough to identify all potential failure modes (FMs), into the FMEA. 

I often see development specialists and FMEA teams that round up one of these block diagrams to describe the system (because they have been told, “they are supposed to", but then make very little if any attempt to use the model to identify Items and failure modes (FMs) to analyze within the FMEA. Even the manager of Reliability and Robust Engineering, at a large company I worked with, did not understand, and could not explain the difference between FM, Failure Modes and SES, System Error States.

To remove FMEA team confusion and reduce total FMEA labor hours and empower teams to easily identify all seen and potential FMs, I combined advantages of various block diagram types into one model/tool called an FBI-Block Diagram (Functional Boundary and Interface-Block Diagram).

The FBI-Block Diagram can be used to: 

What is the Dollar Value of a good FBI-Block Diagram?

The Value of a tool is often hard to quantify, but let's try. If a tool is not used it is of no value. If a tool is used more or less effectively, it is of more or less value. Also, a single tool provides a fraction of the value when using multiple tools (like a saw and a measuring tape, or like the FBI-Block Diagram and the FH-Decomp table), to accomplish a project like FMEA. So, after describing the FH-Decomp Table (below) you will see how and why I put a value of $1,575 on the FBI-Block Diagram. Keep reading and I’ll show you a way you might get these models and tools for free.

Method/Tool 2: FH-Decomp Table

The FH-Decomp table is a valuable FMEA preparation tool to extract all functions and failure modes out of the FBI-Block Diagram, prioritize those functions, so you don’t miss any critical failure modes and quickly organize and populate the FMEA. Refer to the Exhaust System FB-Diagram (above), to see how the FH-Decomp Table is filled in… 

Why do you need an FH-Decomp Table?

Maybe you don’t. Over several years facilitating FMEA groups, I never saw anything like this. But, the very month I discovered the FH-Decomp Table, my job was on the line (at risk of ending). 

Jobs of the other eleven FMEA facilitators in my department were also on the line, about to be eliminated, because the director of systems engineering had given an ultimatum. He had been getting complaints over the last 2-3 years about how much time FMEA was taking away from other engineering duties and complaints that the engineers were still missing critical failure modes (FMs not showing up in the FMEA but manifesting themselves in system verification or validation tests). So, the Director had issued the ultimatum; 

“If you can’t come up with a way to do FMEA a lot faster and show me (justify) that you’re not missing critical FMs, then next quarter we will lay off the FMEA facilitators and contract these services out to an FMEA facilitator services company!”

Well, put it that way, and you’ve got my attention! I felt like our FMEA facilitators knew what they were doing. Most of them were CRE certified. It’s just that management couldn’t look at an FMEA (a spreadsheet with 26 subject columns and 300-500 rows of potential FM information) and make any sense of it. Management was simply confused, I thought. And they don’t like being confused.

So, I started creating this simple Function to Hardware correlation table to show them we did understand the system functions and the component functions (FMEA Items) and how they might fail. When I completed the table and showed the other FMEA facilitators, they discovered that the table helped them identify all possible failure modes and account for them. It also helped them move their FMEA teams much faster through populating the failure modes (FM’s) into the worksheet, in a very systematic fashion. Even,  to identify and prioritize which of these might be most critical.

Management loved it, because they could now see what was going on. The FH-Decomp Table acts like an index and an audit tool for the FMEA. The engineers and FMEA teams loved it because they could very systematically and faster populate the FMEA, with assurance they weren't missing any failure modes (FMs)! The FMEA facilitators loved it because it saved our jobs. No more talk of contracting out FMEA.

Within a month after presenting this FH-Comp Table, my job was ‘locked-in’ secure (And it stayed that way for the next 7 years, until I decided to leave and start my own FMEA services).

Over the next year we documented how much this method/tool was saving us. We knew we were moving much faster and, very logically, without missing any critical failure modes. It gave us rational for more accurately calculating RPN, and later AP. During that next year the accounting department and the Six Sigma Master-Blackbelt Leaders verified that we saved $4,205,817 by completing FMEA activities in less than 1/3rd the time.

Summary Purposes of FH-Decomp Table:

• Helps tie hardware/software blocks (components or Items) to their sub-functions and to the system output function(s).
• Better communicate to management and other development specialists the internal components and their functions (why each is needed).
• Acts as an index to the FMEA and helps identify all functional failure modes going into the FMEA.
• It also serves as an audit tool to ensure critical failure modes are not missed.
• Greatly speeds up population of failure modes into the FMEA.
• Provides rationale, in some cases, to eliminate the FMEA all together.

What is the Value of an FH-Decomp Table?

The value of a tool is only a fraction of the money saved doing the FMEA project.  I started my value calculation for these tools, with the savings all 4 tools helped generate, in reduced FMEA team labor hours. That year, the company saved $4,205,817 by doing their FMEA’s in less than 1/3rd the time. That’s across 40 FMEAs done that year = $105,145.43 per FMEA. I divided that savings by the four 4  preparation tools used = $26,286.36 (value per tool). Of course you could never charge that much for a simple Excel worksheet tool (even if the method for effectively using the tool may reap these kind of savings). So, let's say the worth of the tool is just 6% of the value: $26,286.36 X .06 = $1577.18. That would justify a resale value of $1,575. 

Therefore, the resale value of each tool, when properly used, is a conservative $1,575 for each of these 4 tools. (These savings were verified by the company accounting department and their Six Sigma Project Leaders.)

Method/Tool 3:  The P-Diagram – Template and Example (Excel Worksheets)

• Helps communicate to management and other development specialists the System Functions and malfunctions, caused by; environmental noise factors (stresses) from; manufacturing variables, aging, customer use and miss-use as well as internal stresses and sub-system interactive noise factors. ‘Kind of a graphical model of the entire FMEA and of the system being analyzed.
• It helps correlate stresses and noise factors with design controls, into the FMEA, implemented to prevent malfunction and system failures.
• Helps the FMEA team fill in “End Effect” and SEVerity columns in the FMEA, as well as “cause” and all four “Design Control” columns and think about OCCurrence column scoring.
• Plan and report DVP&R verification and validation testing for the product or system.

Value of the P-Diagram: $1,575

Again, only a fraction of the money ($26,286.36) saved doing a single FMEA project.

Method/Tool 4 of 4 : AIAG VDA Compliant DFMEA Template and Example 

• If you need this FMEA Template, you know why you need it, because it is the new AIAG VDA Standard required for doing DFMEA in the Automotive Industry.
• Puts an emphasis on safety and severity (over detection)
• This AP template automatically adjusts from S X O X D = RPN to AP, Action Priority (on Safety, Criticality and all 4 Design Control types to improve the product or system)

Value of the AIAG VDA DFMEA Template: $1,575

Once again, just a fraction of the money ($26,286.36) saved over a single project.

I've never sold these four FMEA preparation method/tools at any price.  They've only been available to my private clients.

However, right now, because you requested the right Free FMEA template and because I feel some Q&A and Coaching would really help your team, get the most from effective use of these tools, I am offering all four of the above method/tools as a free bonus for those who attend my next online 3-hour workshop titled:

Completing Your DFMEA 3X Faster, without Missing Any Critical Failure Modes

Because you have downloaded the FMEA Template, this $500 workshop is yours for only $187 per attendee.
Attendees will:

1. Receive all four Method/Tools described above, at no additional cost. ($1,575 X 4 = $6,300 Value)
2. Get a working knowledge of these methods and FMEA tools, during the 3 hour online workshop and see…
3. How to complete FMEA activities 3X faster, without missing any critical failure modes.

Attend my online open FMEA workshop this coming Friday at 10:00 AM CST, for only $187 (limit: 15 per session). Or, arrange your own company online private FMEA workshop for $500.00 (limit: 15 per session).

Want to secure your career as an MVP in your company?