Failure Mode and Effects Analysis (FMEA)


This structured approach to risk analysis was originally developed by NASA, and can be used to minimize risk across all manufacturing, service and administration processes. Failure Mode & Effects Analysis (FMEA) is a Risk Assessment / Risk Management (RA/RM) tool used to bullet-proof processes. It works by identifying those potential and actual failure modes that are likely to have significant performance impact.

Scope And Deliverables

The FMEA process involves creating an action plan that proactively addresses potential causes of failure, thereby minimizing the overall risk of failure. The specific action plan also helps ensure that risk mitigation is sustainable. FMEA will also result in improved process controls such that your ability to measure and detect process problems will be enhanced. This methodology is very efficient in terms of the use of resources to improve processes, as it assesses relative risk for all failure modes, and promotes a lean and rational approach to risk assessment, risk mitigation and risk acceptance.

Through the process of executing high-quality FMEAs, your organization will have generated an action plan that will deliver significant process improvement for the targeted business processes.

SatiStar’s FMEA program will transfer capability to your team, such that they can use FMEA thinking and methods effectively in the future to achieve similar results on their own.

The overall outcome is to achieve improved organizational capability enabling you to sustain aggressive and ongoing improvement by means of FMEA methods.

What We Will Do

SatiStar’s FMEA program:

FMEA Project Planning – Establish FMEA projects and document project charter

  • Target processes identified
  • Establish performance metrics and targets
  • Select FMEA team leaders
  • Select FMEA team members
  • Collect necessary data from targeted processes.
  • 2-day FMEA workshop (30% Theory, 60% FMEA on targeted process, 10% post-workshop presentation and planning)

FMEA Analysis & On-going Support

  • FMEA team leaders kick-off post-workshop activities
  • FMEA “experts” selected as internal resources
  • SatiStar facilitates FMEA analysis sessions
  • SatiStar provides technical coaching on FMEA methodology
  • FMEA documents submitted, reviewed by SatiStar and revised
  • FMEA documents (Analysis stage) approved, FMEA resource team given support and coaching

New FMEA projects & team identification

  • Management support & approval sought and received for new FMEA projects
  • Program sustainability built

What We Need You To Do

FMEA “Analysis” Presentation

  • Teams prepare “FMEA analysis presentation” SatiStar provides assistance
  • Teams present to management for Review/ Revision/ Approval with SatiStar in attendance

Risk Mitigation and “Results” Presentation

  • Action plans implemented
  • Performance improvements monitored
  • Teams prepare “FMEA Results Presentation” with SatiStar’s assistance
  • Teams present to management for Review/ Revision/ Approval with SatiStar in attendance
  • Presentation includes FMEA program recommendation including next project


Consulting Overview

Our Services

Performance Breakthrough

Management System Standards

Operational Effectiveness

Leadership and Cultural Transformation

Information Systems

Full Consulting List


SatiStar's Experience Makes The Difference!

  • . . . worked extremely well with the departmental and site managers . . . goal oriented and met the objectives set within the quoted budget and ensured the results were attained for the Company.

  • The guys from SatiStar did more in one week than we were able to do in 6 months.

  • Achieving ISO registration was far less onerous than we thought, our employees really rallied to the cause. The registration effort really brought us closer together as a team, and SatiStar really came through for us when we needed them.

  • We started this process a year ago with Mickey helping us create a spaghetti map of our processes on the whiteboard, and then his team guided us through their streamlining methodology and got us to where we are today. Our processes now look nothing like the spaghetti map – and we’re much more efficient today

  • This projected cycle time reduction of over 80% annual cost savings amounting to over 3% of sales, one-time savings of roughly $10 million, and working capital reduction of roughly $30 million really have us excited!

  • An outstanding success with Motorola’s vendor audit! What made this an exceptional achievement is that it typically takes 4 to 5 attempts to pass this audit. SatiStar’s expertise made it easy to avoid all the extra attempts.