Failure Mode Effects Analysis – FMEA Template for Excel

Failure Mode Effects Analysis – FMEA Template

The Failure Mode Effects Analysis is a great tool used in the Aerospace industry since the 1960s and still in use today for DFM (Design For Manufacturing) in Lean manufacturing environments.  Use our FMEA Template to

  • Identifying the ways in which a product can fail
  • Estimating the risk associated with each failure mode
  • Rank ordering the failure modes to prioritize the design teams efforts
  • Track corrective actions and provide a permanent record for subsequent design and process FMEAs

The main goal of the template is to identify ways that a product can fail and take action to remove the failure modes before they occur

Role of the FMEA Template 

  •  Key tool of the design team to improve the product in a preemptive manner (before failures occur)
  • Used to prioritize resources to insure product development efforts are beneficial to customer
  • Used to document completion of projects
  • Should be a dynamic document, continually reviewed, amended, updated
  • Should serve as starting-point for future DFMEA’s of similar products.
  • Is the catalyst of Process FMEA’s.

Uses for templatestaff\’s Template


  • Used to analyze failures of the end product in a customers system
  • Focuses on potential failure modes associated with the functions of the end product


  • Used to analyze systems and sub-systems of the product in the early concept and design stages
  • Focuses on potential failure modes associated with the functions of each system and sub-system

Component / Material

  • Used to analyze systems and sub-systems down to the fundamental components and materials used in the design
  • Focuses on Components and Material


  • Used to analyze manufacturing and assembly processes
  • Focuses on Process Inputs


How is a Design FMEA different from a Process FMEA?

 The Design FMEA assumes that the process is in control and capable of meeting the process spreads used in the design.  It also assumes that material, and components are performing as specified in the design documentation.

Failures can be caused by:

  • Unclear specifications
  • Inadequate knowledge of environmental conditions
  • Insufficient Analysis, Modelling and Simulation
  • Poor Design
  • Insufficient Testing
  • Not designing for process requirements

Controls are related to the design process:

  • Prevention – Analysis, Simulation and Modelling
  • Detection – Prototype Testing, Design Verification Testing, Reliability Testing

The Process FMEA assumes that the design is capable and focuses on process capability and control.


No tool comes as close as the FMEA when it comes time to prioritize which issues need to be resolved first.

As a result of the FMEA, often encouraged to be preceded by the Ishikawa (fish-bone), and C&E Matrix (Cause & Effect), the RPN (Risk Priority Number) is derived.  This is the product of Importance x Severity x Occurrence (you need to see this in the template firsthand so don\’t hesitate!)

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No Registration Required to Download – Downloads Open to All

If you didn’t know it, has been around for twelve years now.  No kidding. actually started on Joomla 1, migrated to Joomla 2, then finally, on to WordPress, where the site still resides.

Of course, over the years it’s been on WordPress, it’s seen many changes, no less to the back end than to the look.

To make things exciting in celebrating this, we’ve decided to close the registrations.  What does that mean?  It just means that you can now download with just one click.  Over the years, we’ve collected many contacts, however, as we never intended to sell neither your profile nor your data, and the subsequent imposition of GDPR Compliance (General Data Protection Regulations for the EU), we thought, why not?  No need to register anymore.

Operational Excellence Examples in Action

Not spending $1000 on a $100 problem, paying invoices on time, delivering products at the deadline, keeping project costs on budget, coming to work on time, not calling in sick, are not examples of Operational Excellence.  These are just examples of your job and what you’re expected of any given day.

Sometimes, we need to stop and remind ourselves that what when perform our usual tasks well, and sometimes better than well, that doesn\’t necessarily indicate a display of operational excellence.  Operational excellence is about outdoing, outperforming, an outright out-resulting consistently all the time.

Operational Excellence is:

  • Delivering an important feature or product ahead of schedule – by several weeks
  • Paying supplier invoices before Net 30 terms or before negotiated and agreed upon terms
  • Identifying ALL bugs in a product before releasing it – no bugs would be reported by our customers once in their hands – just new feature requests
  • Zero product returns due to defects
  • Zero complaints from our customers
  • Upstream customer feedback flow right to the top of the process
  • Including our customers in our processes
  • Using common tools and repositories to store and collaborate on documents or
  • What examples can you come up with?

Some of you may have worked elsewhere before arriving at the company where an established quality management system existed such as ISO 9001, or Six Sigma.  Some of your experience may be that it was cumbersome and bureaucratic, or that it didn’t deliver the promised results of working for a better company and pleasing customers by delivering superior products or services.

After many employee interviews at the company about your current and past experiences we’ve observed that many of these complaints are the result of a quality management system that was not flexible, and that had not listened to the customer:  You.

Operational Excellence Examples in Action


Free Six Sigma Starter Kit

In all my years as a Six Sigma Black Belt, I’ve never come across such a complete Excel file.  This spreadsheet has 37 tabs in it.  This is more than the number of Excel files I’ve seen in some projects!  I came across this file over the years but I wished I knew who completed it! To me, this is the quintessential Six Sigma starter kit, and it\’s free!

  • Breakthrough Strategy
  • Six Sigma Project Plan
  • Project Action Plan
  • CTQ Template (Critical to Quality)
  • SIPOC (blank)
  • Process Analysis
  • Fishbone
  • Brainstorm
  • Functional Deployment Matrix
  • Risk Assessment
  • Solution Evaluation Form
  • Data Collection Plan
  • Xs and Ys
  • Timeline
  • DOE 22 Factorial
  • DOE 23 Factorial
  • PPM
  • Sigma Level (no shift)
  • RTY (Rolled Throughput Yield)
  • DPMO Calculator (Defects Per Million Opportunities)
  • DPMO to Sigma to Cpk
  • Six Sigma Project
  • GC Plan
  • HOQ (Houses of Quality)
  • C&E Matrix (Cause & Effect)
  • FMEA (Failure Mode and Effects Analysis)
  • FSeverity
  • FOccurrence
  • FDetection
  • Control Plan
  • Process Control Plan
  • Six Sigma Preventive Maintenance
  • Outputs
  • DFMEA Template
  • Z-Table

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Value Stream Map Spreadsheet

Here\’s a new (fourth) value stream map spreadsheet you can use in Microsoft Excel.  The VSM is intended to be a team exercise and maps out in detail the current process and cycle times, then strives to find improvements in the form of reduced cycle time, machine set up time, and overall customer order fulfillment cycle.


Download the here