FMEA (Failure Mode, Effect and Criticality Analysis) management is an essential process for industries, particularly those involved in heat and surface treatments. It enables potential failures to be identified and prevented, thus guaranteeing product reliability and quality. In this interview, Mr. Pascal Fonnesu - HACER Group Quality Manager, and Mr. Lionel Cavalie - HACER Industrial Methods Manager, shed light on the technical and operational advantages of specialized solutions for FMEA management, such as Skill FMEA Pro, over traditional methods such as using Excel.
They detail the benefits of this software capable of managing and linking multiple FMEAs simultaneously, as well as the positive impact on the company's image and the reassurance provided to customers and auditors. The interview also highlights the importance for software publishers of listening to customers' needs and developing their solutions in line with their expectations. Likewise, it highlights the ability of publishers to offer a variety of training and skills-building opportunities for customers to ensure optimal adoption and effective use of their specialized tools.
Can you introduce yourself and the challenges you face with FMEA?
"Pascal Fonnesu, I'm Quality Manager for the HACER Group. The HACER group has five companies, three in surface treatment, two in heat treatment. I'm in charge of management, audits, documentation, and cross-group issues such as FMEA.
Lionel Cavalie, Industrial Methods Manager, I work mainly on three sites where I've been using Skill FMEA Pro software since 2012. Today, three of the group's companies use this solution.
FMEA is often perceived as a "pebble in the shoe" during audits. It requires effective traceability, rigorous document management, and a lot of meeting time not devoted to direct production. It does, however, enable us to anticipate and guarantee future operations. An effective solution like Skill FMEA Pro is therefore essential to optimize this process."
FMEA represents a major challenge for manufacturers, requiring meticulous traceability and strict document management. Audits often reveal that this activity consumes considerable time in meetings, to the detriment of direct production. Yet it is fundamental to anticipating and guaranteeing the smooth future operation of systems.
In fact, carrying out FMEA requires exhaustive data collection on every component and process, including documentation of potential failures, their causes, effects and corrective actions. This process involves various departments, encompassing engineering, production and quality, which accentuates the complexity of coordination.
Optimizing FMEA requires the adoption of advanced technological solutions. Skill FMEA Pro, for example, enables centralized management of FMEA data, automating traceability and simplifying document management. This solution offers real-time collaboration capabilities, reducing the time spent in meetings while improving the accuracy and efficiency of analysis.
FMEA, while demanding in terms of resources and time, remains indispensable for the heat and surface treatment industries, where product reliability and quality are essential. Integrating a solution dedicated to FMEA management represents a strategic investment, reducing long-term costs and improving the overall performance of production processes.
What were the initial motivations that guided the choice for Skill Software as an FMEA software publisher?
"Our decision was influenced by one of our customers who asked us to carry out a FMEA of our installation. We found the Skill FMEA Pro software relevant because it enables us to combine FMEA and monitoring plans in a user-friendly tool. Convinced by the demonstration, we adopted Skill FMEA Pro without looking for other options. Before, we were using Excel, which meant managing several separate documents. This software streamlined this process, offering us significant time savings and better document management."
A customer's recommendation of a service provider has significant power in the corporate decision-making process. Such a recommendation, based on a positive experience, reinforces credibility and trust in the proposed provider, and underlines the importance of customer testimonials in the evaluation and selection of technical solutions.
The simplicity of presentation and use of an FMEA software solution is essential for its adoption and effectiveness. A user-friendly tool must be quick and intuitive to learn, making it easy to integrate into existing processes. Users' clear understanding of features and benefits minimizes resistance to change and optimizes team commitment. An intuitive interface also reduces the need for training and technical support, speeding up deployment of the solution.
The benefits provided by a dedicated FMEA software solution compared with using Excel are varied. Excel, although versatile, has significant limitations when it comes to FMEA management. Using Excel requires the management of several separate documents for FMEAs and monitoring plans, increasing the risk of errors and redundancies. Conversely, a specific FMEA tool makes it possible to combine these elements into a single integrated tool, offering a holistic view of processes.
Can you tell us about the benefits and results observed when using Skill Software's FMEA solution?
"Using Skill FMEA Pro has exceeded our expectations, with the main benefit being time savings. We have reduced the time needed to carry out an FMEA from 35-45 minutes to just 10 minutes, thanks to a single model for the whole company. On files where we have between 150 and 180 FMEAs per year, this is a considerable advantage.
Skill FMEA Pro also enables us to track the evolution of FMEAs, indexes and modify several documents simultaneously, which is very important for efficient management and guaranteeing us a good history. Similarly, as the software is deployed on three of our sites, when we carry out subcontracting with them, it is possible to retrieve the FMEAs from the other sites and integrate them into our FMEAs, and thus have globalized management of our processes.
Also, the solution is well perceived by our customers and auditors, which reinforces our credibility. When they come to consult us and see that we use a FMEA software like Skill FMEA Pro, it reassures them; they quickly understand that it's more efficient than Excel sheets."
Using a software solution specialized in FMEA management offers a number of advantages. In particular, it enables processes to be standardized, making it easier to carry out analyses and reducing variations between different users and departments. A solution capable of centralizing information improves data consistency and traceability. This streamlining inevitably translates into considerable time savings, since all information is brought together and easily accessible.
Managing and linking multiple FMEAs simultaneously is another important asset for companies with complex processes or multiple projects running in parallel. Specialized software capable of linking different FMEAs provides an overview and makes it easier to identify interactions and interdependencies between systems. This ability to manage multiple FMEAs simultaneously improves efficiency and reduces the risk of errors, by enabling global modifications and real-time updating of associated documents.
The impact in terms of image and reassurance with customers and auditors is also significant. The use of a dedicated FMEA tool demonstrates a commitment to best risk management practices and quality. Customers and auditors perceive the company as more professional and reliable, thus reinforcing credibility and trust. During audits, the transparency and accessibility of information, made possible by specialized software, facilitates the process and reduces audit times.
What elements of the Skill FMEA Pro solution and Skill Software support do you find most beneficial?
"As well as being a document management tool, it's a software that links FMEAs together, and offers the possibility of cascading or escalating information, thus enabling data to be capitalized on whatever changes the FMEAs encounter. This is a very positive point, as it saves hours of searching for information, which is much appreciated by the auditors. If we make copies of copies of copies, there's no link, and the day there's an update, it's a mammoth task. Thanks to the FMEA training and Skill Software's solution, we're in the process of overhauling our documentation to be fully AIAG-compliant, and serene during audits.
The other positive point is the evolutions of the solution we benefit from. By giving our feedback to the Skill Software team, we see new functionalities appear, enabling us to gain in efficiency and time. That's something we really appreciate about them, as they really listen to our needs and questions. What's more, as part of a larger group, Skill Software offers the possibility of using other quality solutions, which can be compatible with both Skill software and ERP-type management software.
Finally, the training courses offered by Skill Software are highly adaptable. We've benefited from individual and group training, as well as WebEx sessions, which are very effective for clarifying specific points. Skill Software is very responsive; when we have a problem, we call them and get immediate feedback, which makes it easier for our teams to adopt the software."
Specialized FMEA management software has the ability to link numerous FMEAs together, providing an integrated and consistent view of processes and potential failures. This feature enables information to be cascaded or escalated seamlessly, capitalizing on data regardless of the changes that FMEAs may encounter. This prevents the loss of information and considerably reduces search time, which is particularly appreciated by auditors. By eliminating multiple copies and maintaining links between documents, the software guarantees efficient and accurate updating, avoiding tedious updating work.
Beyond the technical advantages, it's also important for the publisher of FMEA software to listen to customers' needs and expectations for the tool to evolve to better match their specific issues. This responsiveness enables new functionalities to emerge, increasing efficiency and saving time for users. A close relationship with customers helps the editor to better understand the unique challenges faced by each company and adapt the tool accordingly, ensuring a better fit with industrial practices.
FMEA software publishers, such as Skill Software, generally offer a variety of training and skills enhancement opportunities for their customers. Such training can be individual or group-based, and include face-to-face sessions or via online platforms such as WebEx. Proper training ensures that users fully understand the software's functionalities and can use it to its full potential. The publisher's responsiveness to problems and the immediate availability of technical support also facilitate the adoption and daily use of the software by teams.
In addition, editors can offer integration with other quality solutions and ERP-type management software, enabling harmonization of systems and more comprehensive, efficient management of company processes. This enhances interoperability and operational efficiency, while providing a comprehensive and consistent solution for managing FMEAs and other quality needs.
In a few words, how would you describe Skill Software and their Skill FMEA Pro solution?
"Skill Software is a responsive company that has developed software that is user-friendly, relevant, effective, and efficient."
