Case Study – FTS Systems

Applied Failure Modes and Effects Analysis

Situation

An equipment manufacturer was deploying a new lyophilization equipment design primarily targeting the pharmaceutical market. The first wave of the product had been commercially deployed and a number of reliability issues were occurring causing the company to scramble to improve the system design.

Approach

IMPACT consultants led a cross-functional team through a component-based Failure Modes and Effects Analysis (FMEA) focusing on improving operating reliability. The team consisted of both IMPACT engineers and client personnel. FMEA is an easy to use and yet powerful pro-active engineering quality method that helps identify and counter weak points in a product and process. The structured approach makes it easy to use and is a valuable tool for an organization committed to quality work processes and continual improvement.

Results

The team analyzed several hundred failure modes, prioritizing areas requiring re-design and recommending action plans for each component. IMPACT also provided project management oversight for the highest priority action plans.

Client Testimonial

“The IMPACT Team introduced and directed the implementation of FMEA (Failure Modes and Effects Analysis) as a continuous quality improvement tool, and then facilitated its use on one of our critical product lines. They trained our staff and then lead a cross-functional team through the process, developing a prioritized action plan to improve the overall reliability and performance of our equipment. Typical of their hands-on approach, they are now overseeing the action plan and contributing to the technical solution set to ensure that the benefits of the process are realized…higher reliability, lower warranty costs, happy customers.”

– John Chickosky, Vice President of Sales & Marketing, FTS Systems