Risk Management and the Smaller Manufacturer – Part 2

This is the second of a three post series on risk management. Part 1 of this series, posted last week, provides an overview of risk management.  This post, part 2 of the series, reprises and updates a post from 2012. This post provides specific risk management suggestions for smaller manufacturers, especially the use of Failure Modes Effects Analysis (FMEA). Part 3 will focus on the risk management aspects of the new ISO 9001-2015 Standard for Quality Management Systems.

Risk Management for Smaller Manufacturers

(From 13 September 2012)

The previous post to this blog offered some general ideas on risk management. This post addresses risk and the smaller manufacturer. To begin, two points need be clear:

>> Risk Management doesn’t necessarily mean the elimination of risk. Risk is a fact in business, and risk is often the flip side of opportunity. Consider the insurance industry. That industry exists due to risks. Insurance carriers assume risks from others (that is, they sell insurance coverage), and they invest the premiums they receive. Insurance carriers manage risks on both ends: on underwriting and on investment. You can be sure that risk-based industries like the insurance industry understand the risks they take.

Capture - OSHA Incidence Rates>> Look at this graph of manufacturing employee job related injury / illness incidence rates over the past 17 years. The rate at which the incidence rate has improved blows me away. The point here isn’t about safety or OSHA Recordables. The point is that sustained efforts to reduce risk do work, sometimes dramatically.

Failure Mode Effects Analysis 

FMEA, Failure Mode Effects Analysis, provides a powerful tool for identifying, assessing and addressing risks. FMEA can be applied to products, processes and projects. In essence, FMEA provides a framework for looking at possible failure modes (meaning risks), determining the probable frequency of occurrence of each, then the likely severity, then the potential for detecting symptoms of each mode. From these considerations, a risk priority is calculated, so that risk management actions can be prioritized.

FMEA can also be applied to organizational – level matters, including strategic planning.  In particular, FMEA can be used when setting Objectives. By applying FMEA, particularly in conjunction with Ishikawa (“fish-bone”) diagrams, possible impediments to achieving your objectives can be determined and prioritized for pre-emptive actions. A prior post to this blog outlines how this can be done [1].

Capture - FMEABasic introductions to FMEA are available on the web from the American Society for Quality  [2] and from Wikipedia  [3]. Also, there are many books available, starting with an inexpensive 90 page “primer” [4]. If you prefer to use a qualified consultant, you might call your nearest Manufacturing Extension Partnership office for a local referral [5] .

As you may have guessed, FMEA is, in my view, one of the best general purpose tools for managing risk in manufacturing organizations. And managing risks is a key component of navigating the future. The new ISO 9001-2015 Standard for Quality Management Systems [6]  will explicitly require evidence of “risk based thinking”. FMEA provides a valuable tool for compliance.

Chuck - Vancouver3Thoughtful comments and experience reports are always appreciated.


…  Chuck Harrington (Chuck@JeraSustainableDevelopment.com)

P.S. — When it is time for your firm to seriously pursue Sustainability, contact me — C.H.

Note: This blog and associated website (www.JeraSustainableDevelopment.com) are intended as a resource for smaller manufacturers in the pursuit of Sustainability. While editorial focus is on smaller manufacturers, all interested readers are welcome. New blog posts are published weekly.

Images: Illness / injury incidences graph – Jera, using data from the Bureau of Labor Statistics, www.bls.gov. FMEA graphic – Dieter Vanduen, in the public domain, via Wikipedia

[1]  See Green and the Zoom Lens Mind, this blog, http://blog.jerasustainabledevelopment.com/2012/02/22/green-and-the-zoom-lens-mind/

[2]  http://asq.org/learn-about-quality/process-analysis-tools/overview/fmea.html

[3]  http://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis

[4]  Mikulak, R. and R. McDermott and M. Beauregard, Basics of FMEA, Second Edition, Productivity Press, New York (2009)

[5] For the MEP, go to www.NIST.gov/MEP. There is a map of the U.S. Click on your state for local contact information.

[6] The ISO 9001 Standard for Quality Management Systems is expected to be significantly revised and re-issued in 2015.