Critical Success Factors When Implementing Failure Mode and Effects Analysis (FMEA) A Case Study of Process-FMEA at a Global Automotive Manufacturing Company

Abstract

This thesis concerns the implementation of Failure Mode and Effects Analysis (FMEA). There are many different quality tools and practices used today and the implementation greatly impacts the success of the tool. Moreover, FMEA is a common tool but there is limited research on how to best implement it. The purpose of this research was therefore to understand what critical success factors there are when implementing a global FMEA standard. The purpose was fulfilled by firstly studying the literature on FMEA usage and implementation of quality tools and practices. The literary findings resulted in a framework of Critical Success Factors for implementing FMEA. A number of success factors were identified within the following areas: • Leadership • Organizational • Knowledge • Individual • Processual • Stakeholder Management • Contextual • Effective FMEA Practice Secondly, empirical research was performed at a case company that uses Process Failure Mode and Effects Analysis (P-FMEA) and were aiming to implement a new, global P-FMEA according to a handbook on FMEA by Automotive Industry Action Group (AIAG) and Verband der Automobilindustrie (VDA). The empirical findings were analyzed based on the theoretical framework. Lastly, the findings from the analysis were used to create recommendations for the implementation of P-FMEA and representatives from the case company participated in a workshop to prioritize the recommendations based on feasibility and impact. Some of the recommendations were considered quick-wins, such as establishing senior management support at all sites, while