Failure Mode &
Effects Analysis.
FMEA (Failure Mode and Effects Analysis) is a systematic method for identifying potential failure modes, their causes, effects, and consequences. Reliatic automates FMEA workflows with state machine enforcement, versioning, and rules-based risk prioritization.
01. FMEA Overview
FMEA is a proactive risk assessment technique used to analyze potential failure modes in equipment and processes. Each failure mode is evaluated based on three factors: Severity, Occurrence (Likelihood), and Detection, which together determine the Risk Priority Number (RPN).
Severity (S)
Impact of the failure on safety, operations, and business. 10 = catastrophic, 1 = negligible.
Occurrence (O)
Likelihood of the failure mode occurring. 10 = very high frequency, 1 = extremely unlikely.
Detection (D)
Ability to detect the failure before it occurs. 10 = cannot detect, 1 = always detected.
Why FMEA Matters
- Proactive identification of high-risk failure modes before incidents occur
- Prioritized action plans based on quantified risk scores
- Compliance with ISO 31000, API 580, and industry standards
- Audit trail of engineering decisions and risk mitigation strategies
02. RPN Calculation
RPN = Severity × Occurrence × Detection
Critical Threshold: RPN ≥ 125
Example Calculation
03. Creating FMEA Records
Navigate to Asset
Go to Dashboard > Assets and select the equipment you want to analyze.
Open FMEA Tab
Click the 'FMEA' tab in the asset detail view to see existing failure modes or create new ones.
Click 'New Failure Mode'
Click the 'Add Failure Mode' button to open the FMEA creation form.
Describe Failure Mode
Enter a clear description of how the asset could fail (e.g., 'External corrosion leading to wall thinning').
Identify Effect
Describe the consequences if this failure occurs (e.g., 'Loss of containment, hydrocarbon release').
Determine Cause
Identify root causes (e.g., 'Inadequate coating, moisture exposure, chloride attack').
Rate S, O, D
Assign numerical ratings for Severity (1-10), Occurrence (1-10), and Detection (1-10).
Set Review Interval
Define how often this FMEA should be reviewed (e.g., 12 months for high-risk, 24 months for low-risk).
Assign Ownership
Select the FMEA owner (responsible for periodic review) and optionally assign action/escalation owners.
Save & Calculate
Click 'Create'. The system calculates RPN and schedules the next review date.
04. Risk Prioritization Matrix
Critical Risk
RPN ≥ 200Immediate action required. Escalate to management. Create mitigation plan within 48 hours.
High Risk
125 ≤ RPN < 200Action plan required within 2 weeks. Assign action owner and target completion date.
Medium Risk
80 ≤ RPN < 125Monitor and review. Consider preventive measures. Action plan recommended but not mandatory.
Low Risk
RPN < 80Accept risk. Continue routine inspections and monitoring. No immediate action needed.
Suggested Actions by RPN Level
- RPN ≥ 125: System creates a risk event, sends notification to escalation owner, and marks FMEA as "requires action"
- Review Overdue: Automatic status change to "stale" and alert sent to FMEA owner
- Governance Policy Breach: Workflow enforcement prevents RPN updates without justification and approval
05. FMEA State Machine
Reliatic enforces a state machine for FMEA lifecycle management. This ensures that all status transitions are valid, audited, and compliant with governance policies.
draft → active // Initial activation active → under_review // Periodic review started under_review → active // Review completed, FMEA valid under_review → archived // Obsolete, no longer applicable active → stale // Review overdue (automatic) stale → under_review // Late review initiated stale → archived // Permanently retired
06. FMEA Review Workflow
Automatic Review Alert
30 days before the next review date, the system sends an email notification to the FMEA owner.
Start Review Process
Owner clicks 'Start Review' to transition FMEA from 'active' to 'under_review' status.
Re-evaluate S, O, D
Review and update Severity, Occurrence, and Detection ratings based on current conditions, inspection results, and incident history.
Update Mitigation Actions
Document any changes to controls, safeguards, or mitigation measures implemented since last review.
Provide Justification
Enter a justification note explaining any RPN changes or confirming that the assessment remains valid.
Complete Review
Click 'Complete Review'. System creates a versioned snapshot of the FMEA with timestamp and actor ID.
Automatic Re-scheduling
Next review date is calculated based on the review interval (e.g., +12 months).
07. Best Practices
Be Specific with Failure Modes
Avoid generic descriptions like 'equipment failure'. Instead, specify the exact failure mechanism: 'Stress corrosion cracking in weld heat-affected zone'.
Use Cross-Functional Teams
Involve operations, maintenance, engineering, and safety personnel in FMEA reviews for comprehensive risk assessment.
Link to Inspection Results
Reference specific inspection findings, thickness readings, or NDT results when updating RPN values.
Document Assumptions
Record all assumptions made during S, O, D rating assignments in the justification field for future reviewers.
Prioritize by RPN, Not Just Severity
Don't ignore low-severity failures with high occurrence rates. RPN captures the combined risk profile.
Review After Incidents
When a failure occurs, immediately review the related FMEA and update ratings based on new evidence.
Set Realistic Review Intervals
High RPN failures (≥200): 6-12 months. Medium RPN (80-200): 12-18 months. Low RPN (<80): 24-36 months.