Failure Mode and Effects Analysis

 

Any business in the manufacturing industry would know that anything can happen in the development stages of the product. And while you can certainly learn from each of these failures and improve the process the next time around, doing so would entail a lot of time and money.
A widely-used procedure in operations management utilised to identify and analyse potential reliability problems while still in the early stages of production is the Failure Mode and Effects Analysis (FMEA).

FMEAs help us focus on and understand the impact of possible process or product risks.

The FMEA method for quality is based largely on the traditional practice of achieving product reliability through comprehensive testing and using techniques such as probabilistic reliability modelling. To give us a better understanding of the process, let’s break it down to its two basic components ? the failure mode and the effects analysis.

Failure mode is defined as the means by which something may fail. It essentially answers the question “What could go wrong?” Failure modes are the potential flaws in a process or product that could have an impact on the end user – the customer.

Effects analysis, on the other hand, is the process by which the consequences of these failures are studied.

With the two aspects taken together, the FMEA can help:

  • Discover the possible risks that can come with a product or process;
  • Plan out courses of action to counter these risks, particularly, those with the highest potential impact; and
  • Monitor the action plan results, with emphasis on how risk was reduced.

Find out more about our Quality Assurance services in the following pages:

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Spreadsheet Reporting – No Room in Your Company in an Age of Business Intelligence

It doesn’t take a genius to understand why spreadsheet reporting still pervades the enterprise despite the rise of a complex but highly effective IT solution known to big shot CIOs as Business Intelligence or BI.

If you’re still in the dark as to what BI is, don’t worry because we?ll enlighten you shortly.

Business decisions from disparate data sources

In the meantime, let’s talk about how you make business decisions. If you’re a top executive, then you make decisions based largely on reports submitted to you by your managers, department heads, and so on. They in turn obtain information from different sources, like the company ERP and CRM as well as other external sources (e.g. market surveys).

Now, before their reports ever reach your desk, a lot of data is extracted, shared, filtered, analysed, consolidated, and summarised so that they become actionable information. In all these activities, one software tool gets to take part in most of the action – the spreadsheet.

The problem with spreadsheet reporting

The problem with spreadsheets is that they have very poor built-in controls. Thus, they are susceptible to human errors and are vulnerable to fraud. What’s more, collecting data and manually consolidating them into spreadsheets can be very laborious and time consuming.

If you don’t get accurate, reliable information, your judgement will be fuzzy and your business decisions compromised. In addition, if you don’t receive the information you need on time, your business will constantly be at risk of breaching critical thresholds, which may even force it to spin out of control.

Business Intelligence – actionable information on time

This is mainly the reason why large companies implement Business Intelligence systems. BI systems are equipped with built-in features like reports, dashboards, and alerts.

Reports consolidate data and present them in a consistent format composed of intuitive text, graphs, and charts. The main purpose of having a consistent format is so that you will know what kind of information to expect and how the information is arranged. That way, you don’t waste time searching or making heads or tails out of the data in front of you.

Dashboards, on the other hand, present information through visual representations composed of graphs and gauges that are aimed at tracking your business metrics and goals. The main function of dashboards is to feed you with actionable information at a glance.

Finally, alerts keep you informed when certain conditions are met or critical thresholds are breached. Because their main purpose is to prompt you at the soonest possible time wherever you are, a typical alert can come in the form of an SMS message or an email.

As you can see, all three features are designed to get you making well-informed decisions as quickly as possible.

The problem with Business Intelligence and the alternative solution

The usual problem with full BI systems is that they can be very costly. Hence, if your organisation does end up implementing one, chances are, not everyone under you will be able to access it. As a result, some departments will be forced to go back to using spreadsheets.

If your company cannot afford a full BI system, then that probably means you don’t need one. What you need is a more affordable alternative. There are actually Software as a Service (SaaS) Business Intelligence solutions that may not be as comprehensive as a full BI system, but which may suffice for small and mid-sized businesses.

The disadvantages of spreadsheets are more damaging than you could have ever expected. Be free of it now.

 

More Spreadsheet Blogs

 

Spreadsheet Risks in Banks

 

Top 10 Disadvantages of Spreadsheets

 

Disadvantages of Spreadsheets – obstacles to compliance in the Healthcare Industry

 

How Internal Auditors can win the War against Spreadsheet Fraud

 

Spreadsheet Reporting – No Room in your company in an age of Business Intelligence

 

Still looking for a Way to Consolidate Excel Spreadsheets?

 

Disadvantages of Spreadsheets

 

Spreadsheet woes – ill equipped for an Agile Business Environment

 

Spreadsheet Fraud

 

Spreadsheet Woes – Limited features for easy adoption of a control framework

 

Spreadsheet woes – Burden in SOX Compliance and other Regulations

 

Spreadsheet Risk Issues

 

Server Application Solutions – Don’t let Spreadsheets hold your Business back

 

Why Spreadsheets can send the pillars of Solvency II crashing down

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Importance of Field Service Management Software for Mobile Working

Technology has been evolving at a fast pace. Changes are also happening simultaneously within different industries. Making a great difference in the business world right now is the trend of mobile working.

Thanks to platforms and tools, working while on the go is now easier and more streamlined. The field service industry also benefits from these technological advances.

Mobile technicians can now give excellent performance and do their job efficiently with no hands-on management needed.

Keep in mind that field service management is no joke. So, to achieve a smooth business and mobile worker management, you’ll need to invest in good mobile service management software.

But First, what is Mobile Working?

Mobile working is a method of working that is not tied to a single physical location.

It isn’t just about checking your emails on your phone or ringing your colleagues via Bluetooth while driving your car to the next appointment. It’s so much more intricate than that.

Effective mobile working means you’re mobilising your workers. Field technicians should have everything they need to complete their day to day work. You’re giving them their entire office in the form of a mobile device.

Mobile working, via a handheld device, allows field technicians to do the following:
● Access and input information about a work order
● Collaborate on projects
● Stay in touch with colleagues, clients and management
● Utilize effectively the different software features

Your field workers should have the support of a dynamic management tool that ensures they are sent to the job that utilises their skills effectively and efficiently.

That’s where a good field service management software shows its importance.

The Role of a Field Service Management Software

Your mobile workforce is scattered across various physical locations. You’ll need to connect with them and simultaneously manage your field service business.

Thanks to the increasing connectivity and improvement of technologies for this purpose, mobile workers can easily input and access any work order details via your chosen field service management software.

What Makes a Good Field Service Management Software?

There are 3 main points to consider when investing in a good mobile workforce management software:

1. It’s simple and familiar to use. Like we mentioned before, be sure to mobilise your field technicians – not the back-office system. Make sure your chosen app or software has a simple user interface so your workers can be on-the-go easily.

2. It works offline. Rural areas and highways can have poor connectivity. Sometimes agents will need to work in areas that have little to no network coverage or are deep down working in tunnels or around heavy machines and turbines. You don’t want your field technicians unable to complete work due to connectivity issues. Make sure to choose software that can function on their device while offline.

3. It’s flexible (and maintainable). Your field service management of choice should have real-time visibility. Flexible and improved visibility for a field worker means that they can do their best in any task. They can share or get critical information about orders and customers. This drastically improves job completion rates and customer satisfaction.

Importance of Field Service Management Software to Mobile Working

Utilize the technology that is available to you. Your mobile workforce should have the right tools so they can make sure to do their fieldwork efficiently without worrying about tedious administrative work. Any back-office task can be done quickly through a field service management software.

And that’s the most important role of a great mobile service management app — effective mobile worker efficiency.

Benefits of a Field Service Management Software to Mobile Working

● Additional revenue: By simplifying the administrative work, your field technician can even double the work order in their daily shift, meaning more profit for the business.

● Cost-cutting: The cloud-based nature of a field service management software means that your business can reduce the cost of on-site IT.
Your mobile workforce can operate from wherever they have an online connection, meaning less reliance on offices and building costs.

● Boosts overall efficiency: A mobile workforce management software allows you as a manager to monitor in real-time where they are and what they are doing. It means that problems can be identified and dealt with immediately.
Your field technician, in turn, becomes more efficient because the technology allows them a quicker response, instead of taking too long finishing administrative tasks.

Invest in a great field service management software. Check out FieldElite and see how they can help you with the following mobile working features:
• Accepts jobs in the field
• Automate appointment scheduling
• Manage scheduled jobs
• Get real-time visibility into all operations
• Have a clear and easy viewing of job locations
• Resolve field service calls faster
• Enable mobile workers to get the job done right
• Keep customers updated at every step
• Create quotations and accept payments
• Analyse efficient reports from field technicians

How Mid-South Metallurgical cut Energy Use by 22%

Mid-South in Murfreesboro, Tennessee operates a high-energy plant providing precision heat treatments for high-speed tools – and also metal annealing and straightening services. This was a great business to be in before the energy crisis struck. That was about the same time the 2009 recession arrived. In no time at all the market was down 30%.

Investors had a pile of capital sunk into Mid-South?s three facilities spread across 21,000 square feet (2,000 square meters) of enclosed space. Within them, a number of twenty-five horsepower compressors plus a variety of electric, vacuum and atmospheric furnaces pumped out heat 27/7, 52 weeks a year. After the company called in the U.S. Department of Energy for assistance, several possibilities presented.

Insulate the Barium Chloride Salt Baths

The barium chloride salt baths used in the heat treatment process and operating at 1600?F (870?C) were a natural choice, since they could not be cooled below 1200?F (650?C) when out of use without hardening the barium chloride and clogging up the system. The amount of energy taken to prevent this came down considerably after they covered and insulated them. The recurring annual electricity saving was $53,000.

Manage Electrical Demand & Power

The utility delivers 480 volts of power to the three plants that between them consume between 825- and 875-kilowatt hours depending on the season. Prior to the energy crisis Mid-South Metallurgical regarded this level of consumption as a given. Following on the Department of Energy survey the company replaced the laminar flow burner tips with cyclonic burner ones, and implemented a number of other modifications to enhance thermal efficiency further. The overall natural gas reduction was 20%.

Implement Large Scale Site Lighting Upgrade

The 24/7 nature of the business makes lighting costs a significant factor. Prior to the energy upgrade this came from 44 older-type 400-watt metal halide fixtures. By replacing these with 88 x 8-foot (2.5 meter) fluorescent fittings Mid-South lowered maintenance and operating costs by 52%

The Mid-South Metallurgical Trophy Cabinet

These three improvements cut energy use by 22%, reduced peak electrical demand by 21% and brought total energy costs down 18%. Mid-South continues to monitor energy consumption at each strategic point, as it continues to seek out even greater energy efficiency in conjunction with its people.

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