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FMEA & Equipment Criticality

Failure Modes and Effects Analysis (FMEA) and equipment criticality ranking for maintenance and reliability professionals: working the FMEA worksheet, scoring severity, occurrence and detection, using risk priority sensibly, ranking assets on a consequence x likelihood matrix, and turning criticality into maintenance, spares and inspection decisions.

54m
Total time
4
Competency levels
12
Lessons

What you'll learn

  • Explain the purpose of FMEA and work the worksheet flow from function through failure mode, effect, cause, controls and actions
  • Score severity, occurrence and detection against agreed anchored scales and calculate a risk priority number
  • Describe the known limitations of RPN and apply severity-first action thresholds instead of a single cut-off
  • Rank equipment criticality using a consequence x likelihood matrix that covers safety, environment, production and cost
  • Use criticality to select maintenance strategy, set spares stocking decisions and prioritise inspection and backlog work
  • Keep FMEAs alive by feeding incidents, repeat failures and modifications back into the analysis

Curriculum

Progress through each competency level in order.

1

Awareness

  • What FMEA Is For and How the Worksheet Flows
    Knowledge
    3m
  • Scoring Severity, Occurrence and Detection
    Knowledge
    3m
  • Awareness Check: FMEA Foundations
    Assessment
    7m
2

Knowledge

  • RPN, Its Limitations, and Better Action Thresholds
    Knowledge
    3m
  • Ranking Equipment Criticality
    Knowledge
    3m
  • Knowledge Check: Risk Priority and Criticality
    Assessment
    8m
3

Skill

  • Turning Criticality into Strategy, Spares and Inspection
    Knowledge
    3m
  • Assignment: FMEA and Criticality Ranking for One System
    Assignment
    3m
  • Skill Check: Applying FMEA and Criticality
    Assessment
    8m
4

Mastery

  • Keeping FMEAs and Criticality Rankings Alive
    Knowledge
    3m
  • Assignment: Revalidate an Analysis Against Operating Experience
    Assignment
    3m
  • Mastery Assessment: Sustaining the Analysis
    Assessment
    7m

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