{"id":3034,"date":"2026-04-01T15:27:15","date_gmt":"2026-04-01T15:27:15","guid":{"rendered":"https:\/\/unternehmensberatung-jarosch.com\/?p=3034"},"modified":"2026-04-01T15:41:31","modified_gmt":"2026-04-01T15:41:31","slug":"reverse-fmea","status":"publish","type":"post","link":"https:\/\/unternehmensberatung-jarosch.com\/en\/reverse-fmea\/","title":{"rendered":"Reverse FMEA"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"3034\" class=\"elementor elementor-3034\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-7a9ddd8 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"7a9ddd8\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-a665cdd elementor-widget elementor-widget-image\" data-id=\"a665cdd\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"800\" height=\"423\" src=\"https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Reverse-FMEA-2-1024x541.jpg\" class=\"attachment-large size-large wp-image-3038\" alt=\"\" srcset=\"https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Reverse-FMEA-2-1024x541.jpg 1024w, https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Reverse-FMEA-2-300x159.jpg 300w, https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Reverse-FMEA-2-768x406.jpg 768w, https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Reverse-FMEA-2.jpg 1126w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-6023451 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"6023451\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-9e1a0e5 elementor-widget elementor-widget-heading\" data-id=\"9e1a0e5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h2 class=\"elementor-heading-title elementor-size-default\">Reverse FMEA<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-9684836 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"9684836\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-460a7c3 elementor-widget elementor-widget-text-editor\" data-id=\"460a7c3\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>A blog by Dr. Uwe-Klaus Jarosch, April 2026<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-e47f56b e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"e47f56b\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-f7d4efb elementor-widget elementor-widget-text-editor\" data-id=\"f7d4efb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Especially when it comes to manufacturing processes, customers have a vital interest in ensuring that what was developed and agreed upon and, if necessary, approved during the launch phase actually happens in the real-world process.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-785ade0 elementor-widget elementor-widget-text-editor\" data-id=\"785ade0\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>During the planning phase, all sorts of possibilities may have been considered or promised, but ultimately what counts is what actually materializes and is implemented in the shop floor process.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d4ef3d0 elementor-widget elementor-widget-text-editor\" data-id=\"d4ef3d0\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Experience shows that there can be a significant difference between theory and practice. But this shouldn\u2019t be.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-dd8dc5e elementor-widget elementor-widget-text-editor\" data-id=\"dd8dc5e\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>This is where the Reverse FMEA method comes in\u2014if one wishes to call it a \u201cmethod\u201d at all. Unfortunately, Reverse FMEA is not a generally standardized method.<\/p><p>The term is primarily used in the automotive industry, and individual OEMs provide both process descriptions and require suppliers to perform a Reverse FMEA.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-25372e1 elementor-widget elementor-widget-text-editor\" data-id=\"25372e1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><strong>Objectives of a Reverse FMEA<\/strong><\/h4>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7a110b1 elementor-widget elementor-widget-text-editor\" data-id=\"7a110b1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>What are the goals here?<\/p><p>The basic idea is to conduct a systematic comparison between the source document, the \u201cProcess FMEA,\u201d and its implementation in the actual process. It serves as a reality check for the content of the P-FMEA. If this comparison is to be conducted thoroughly and consistently, a significant amount of time must be allocated for it.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ded1d87 elementor-widget elementor-widget-text-editor\" data-id=\"ded1d87\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Some customers, such as the U.S. OEM General Motors, specify in their reverse FMEA process that individual process stages must be reviewed in accordance with a schedule. For longer, complex manufacturing processes, conducting the reverse FMEA can take several weeks and incur correspondingly high costs.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-4d5ab98 elementor-widget elementor-widget-text-editor\" data-id=\"4d5ab98\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>If the reverse FMEA is mandated internally within a company, this reflects, to some extent, the realization that the actual FMEA process is not sufficiently aligned with practical reality. This can be particularly true when planning departments operate far removed from production and\/or have no direct insight into what is happening on the production line.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-fb256cb elementor-widget elementor-widget-text-editor\" data-id=\"fb256cb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>In my view, two key questions are expected to be addressed by a reverse FMEA:<\/p><ul><li>Have the measures from the PFMEA been implemented and are they effective?<\/li><li>Are there still opportunities for improvement in the actual process that should be incorporated into the PFMEA?<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-12ca9ed elementor-widget elementor-widget-text-editor\" data-id=\"12ca9ed\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>For both questions, it is also expected that any identified shortcomings will be addressed.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-15facb8 elementor-widget elementor-widget-text-editor\" data-id=\"15facb8\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>When we talk about the Process FMEA, this is a document that is generally unknown on the shop floor, or at least not available there. What should be known, available, and directly or indirectly implemented in production is the Production Control Plan (PCP) with its supplementary work and inspection instructions.<\/p><p>In digitally controlled manufacturing (via MES <a href=\"#_ftn1\" name=\"_ftnref1\">[1]<\/a>), these documents are converted into a chain of digital instructions and inputs and are additionally networked with production control, so that, for example, the instructions and data collection for each individual order are executed with perfect fit. Process control is carried out by this system. Work instructions and inspection plans are displayed to employees directly at the workplace, and inspection results are requested until they are fully recorded.<\/p><p style=\"padding-left: 40px;\"><a href=\"#_ftnref1\" name=\"_ftn1\">[1]<\/a> MES = Manufacturing Execution System, see my blog post<span style=\"text-decoration: underline;\"><span style=\"color: #0000ff;\"> <a style=\"color: #0000ff; text-decoration: underline;\" href=\"https:\/\/unternehmensberatung-jarosch.com\/von-der-p-fmea-zum-mes-folge-3\/\">From P FMEA to MES (3) \u2013 Unternehmensberatung Jarosch<\/a><\/span><\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d86070a elementor-widget elementor-widget-text-editor\" data-id=\"d86070a\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>From this perspective, the reverse FMEA can be broken down into three steps:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-7a821aa e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"7a821aa\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-a822208 elementor-widget elementor-widget-image\" data-id=\"a822208\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"775\" height=\"537\" src=\"https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Kreislauf-in-Reverse-FMEA.jpg\" class=\"attachment-large size-large wp-image-3037\" alt=\"\" srcset=\"https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Kreislauf-in-Reverse-FMEA.jpg 775w, https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Kreislauf-in-Reverse-FMEA-300x208.jpg 300w, https:\/\/unternehmensberatung-jarosch.com\/wp-content\/uploads\/2026\/04\/Kreislauf-in-Reverse-FMEA-768x532.jpg 768w\" sizes=\"(max-width: 775px) 100vw, 775px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-292d4d4 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"292d4d4\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-026d1a1 elementor-widget elementor-widget-text-editor\" data-id=\"026d1a1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>1.)\u00a0\u00a0\u00a0 Document comparison:<\/p><p>Does the PCP contain all steps and all production and inspection equipment used?<\/p><p>Does it include all measurements and inspections specified in the P-FMEA before, during, and after the process run?<\/p><p>If not, are there agreed-upon rules regarding what must be included and what does not need to be specified <a href=\"#_ftn1\" name=\"_ftnref1\">[2] <\/a>?<\/p><p>Do the inspection frequencies and control methods align with what is required for the O and D evaluations of the status of corrective actions?\u00a0\u00a0<\/p><p style=\"padding-left: 40px;\"><a href=\"#_ftnref1\" name=\"_ftn1\">[2]<\/a> <em>Example: A robot has a track control. This control will measure the angle of each axis by every millisecond. It will send it to the controller for instant check and for next motor impulses to adress direction and speed of movement. This closed loop circle from my view should NOT be part oft he PCP. Wheathis this part of process control needs to be mentioned in the P FMEA may be decided differently but will not influence the robot function.<\/em><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-488c907 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"488c907\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-f373e4c elementor-widget elementor-widget-text-editor\" data-id=\"f373e4c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>2.)\u00a0\u00a0\u00a0\u00a0 Shop Floor Walk &#8211; Gemba:<\/p><p>Are all steps that occur in the process and are listed in the PCP also considered identically in the P-FMEA?<\/p><p>Are employees involved in the process aware of any additional potential problems or errors that could occur in the process outcome (focus level) or at the root cause level but are not specified in the P-FMEA?<\/p><p>Do the assessments of the status of corrective actions align with on-the-shop-floor experience?<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6de8680 elementor-widget elementor-widget-text-editor\" data-id=\"6de8680\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>3.) Lessons Learned:<\/p><p>Are unplanned rework and scrap rates from similar manufacturing processes\u2014or even from current production\u2014accurately reflected in the assessments? Have changes been implemented relative to the original plan that are still missing in the P-FMEA?<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1fb7d3c elementor-widget elementor-widget-text-editor\" data-id=\"1fb7d3c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><strong>When should the reverse FMEA be conducted?<\/strong><\/h4>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-5b39f4b elementor-widget elementor-widget-text-editor\" data-id=\"5b39f4b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>The timing and scope depend heavily on who is requesting the procedure.<\/p><ul><li>Customer requirement: As part of the initial sampling process, i.e., before the process receives series production approval.<\/li><li>Customer requirement or standard procedure at the supplier: Regular, e.g., annual repetition.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-db2b584 elementor-widget elementor-widget-text-editor\" data-id=\"db2b584\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Since the effort involved in a thoroughly conducted reverse FMEA is considerable, the balance between effort and added value must be given.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-6e3a6a4 elementor-widget elementor-widget-text-editor\" data-id=\"6e3a6a4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>If a company internally requires that a process FMEA be reviewed and optimized using a reverse FMEA, it should specifically address shortcomings.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1115816 elementor-widget elementor-widget-text-editor\" data-id=\"1115816\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>One potential shortcoming could be that, during the development of the P-FMEA, it was not the line employees who participated, but \u201conly\u201d experts with no direct involvement in production.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-a851c9f elementor-widget elementor-widget-text-editor\" data-id=\"a851c9f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Another potential shortcoming could be that there is a systematic use of template FMEAs, which means that the gap between theory and practice remains significant.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b07e42d elementor-widget elementor-widget-text-editor\" data-id=\"b07e42d\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>In my experience, a third potential shortcoming only emerges over time: processes in series production are subject to change. These changes can stem from improvements identified in daily operations, but also from responses to internal or external complaints, product upgrades, lessons learned from issues elsewhere, adjustments resulting from Lean Management analyses, fluctuations in production volume, and much more.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b0ae1c2 elementor-widget elementor-widget-text-editor\" data-id=\"b0ae1c2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>What does the process look like within the company to keep the P-FMEA up to date in the face of such changes?\u00a0<\/p><p>If this maintenance is not well-established, the reverse FMEA could provide the necessary follow-up maintenance at a set interval.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-aaab0e1 elementor-widget elementor-widget-text-editor\" data-id=\"aaab0e1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Since the P-FMEA should be created when the actual production is not yet available in its series version, it is also unrealistic to go into the process and see how it is realy implemented.\u00a0<\/p><p>The P-FMEA is supposed to be part of advance planning and enable decision-making. Once everything has been fully implemented, the P-FMEA is too late.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-352e5cb elementor-widget elementor-widget-text-editor\" data-id=\"352e5cb\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>The Reverse-FMEA, on the other hand, only makes sense once implementation is well underway. In automotive APQP, we refer to this as the process series, the 300-unit program, or Run@Rate. These production phases take place before final process approval. They are conducted to verify production readiness.<\/p><p>This phase is filled with a great many activities on the shop floor. Therefore, process managers and all employees will be \u201coverjoyed\u201d if they are allowed to \u201calso\u201d support a reverse FMEA. It must therefore truly help them to be actively supported.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f736df1 elementor-widget elementor-widget-text-editor\" data-id=\"f736df1\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><strong>But at the end of the pre-series, when the process should actually be ready for series production, the reverse FMEA offers the best cost-to-effect ratio.<\/strong><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7b7cb6b elementor-widget elementor-widget-text-editor\" data-id=\"7b7cb6b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><strong>Failure Culture<\/strong><\/h4>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8c48836 elementor-widget elementor-widget-text-editor\" data-id=\"8c48836\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Another factor to address is the company\u2019s overall failure culture:<\/p><p>If the typical approach is to wait until something goes wrong and then react with a firefighting response, employees are under constant stress. This constant stress is caused by the fact that the \u201cold\u201d production lines do not run smoothly, rework and extra work are caused by scrap parts, and, in addition, special measures requested by the customer in response to complaints must be handled in time and again. All of these unplanned efforts deprive the team of the capacity to adequately prepare for the next project, to properly secure that project, and then to work without disruptions.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-dbb4c60 elementor-widget elementor-widget-text-editor\" data-id=\"dbb4c60\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>When a reverse FMEA is conducted, it should help to reconcile advance planning with implementation BEFORE series production begins and also fully incorporate lessons learned from other projects. Otherwise, unplanned extra work, customer pressure, and operational disruptions due to retrofits and unnecessary repairs are \u201cinevitable.\u201d<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-cc7bc25 elementor-widget elementor-widget-text-editor\" data-id=\"cc7bc25\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h4><strong>What is the reverse FMEA neither intended for nor suited to?<\/strong><\/h4>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8a45bba elementor-widget elementor-widget-text-editor\" data-id=\"8a45bba\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Reverse FMEA is a systematic review of planning documents against the documents available in production. This goes far beyond a random check, such as that performed in a process audit.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1c3adf4 elementor-widget elementor-widget-text-editor\" data-id=\"1c3adf4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Conversely, reverse FMEA is not a method that can be applied continuously. The effort involved is too high for that. It is by no means a substitute for the continuous updates required in the context of changes (as listed above). Depending on the industry, there is a strict requirement that P-FMEA and PCP MUST correspond to the current status and workflow of production. This cannot be achieved by Reverse-FMEA under any circumstances, not even with \u201cregular\u201d repetition.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c0af477 elementor-widget elementor-widget-text-editor\" data-id=\"c0af477\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>In my view, the effort involved in a reverse FMEA becomes pointless if the P-FMEA is created seriously, with competent facilitation, AND with the direct participation of colleagues from production. In that case, the expected gain in insights is no longer significant. The effort is no longer justifiable given the benefits.\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-8756ba8 e-flex e-con-boxed elementor-invisible e-con e-parent\" data-id=\"8756ba8\" data-element_type=\"container\" data-e-type=\"container\" data-settings=\"{&quot;animation&quot;:&quot;fadeIn&quot;}\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t<div class=\"elementor-element elementor-element-ea43be2 elementor-widget elementor-widget-text-editor\" data-id=\"ea43be2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"color: #ff0000;\"><strong>Conclusions:\u00a0<\/strong><\/span><\/p><ul><li>Reverse-FMEA is time-consuming.<\/li><li>Reverse-FMEA is significantly more intensive than an audit, as it is intended to be a systematic review rather than a random sample.<\/li><li>Reverse FMEA verifies whether the contents of the process FMEA (theory) have been implemented in production (practice).<\/li><li>Reverse FMEA can also incorporate experiences into the process FMEA that were not (yet) available at the time of its creation.<\/li><li>Despite numerous concurrent tasks with limited ressources at the end of the pre-series phase, this seems to me to be the most appropriate time for a reverse FMEA.<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8dd9987 elementor-widget elementor-widget-text-editor\" data-id=\"8dd9987\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: right;\">Stay curious<br \/><br \/>Yours\u00a0 <br \/>Uwe Jarosch<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-168aa5e e-flex e-con-boxed e-con e-parent\" data-id=\"168aa5e\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Was von der Prozess-FMEA (Theorie) ist in der Fertigungslinie angekommen (Praxis) angekommen. Die Reverse-FMEA kl\u00e4rt es und bessert notfalls nach.<\/p>\n","protected":false},"author":1,"featured_media":3038,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_themeisle_gutenberg_block_has_review":false,"footnotes":""},"categories":[158,152,155,160],"tags":[352,356,353,354,24,305,115,350,351,355],"class_list":["post-3034","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-entwicklungsmethoden","category-mit-methode","category-qualitaetsvorausplanung","category-wissensmanagement","tag-audit","tag-begehung","tag-dokumentenvergleich","tag-gemba","tag-lessons-learned","tag-p-fmea","tag-plp","tag-reverse","tag-reverse-fmea","tag-vor-ort"],"_links":{"self":[{"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/posts\/3034","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/comments?post=3034"}],"version-history":[{"count":11,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/posts\/3034\/revisions"}],"predecessor-version":[{"id":3050,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/posts\/3034\/revisions\/3050"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/media\/3038"}],"wp:attachment":[{"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/media?parent=3034"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/categories?post=3034"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/unternehmensberatung-jarosch.com\/en\/wp-json\/wp\/v2\/tags?post=3034"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}