FMECA vs. FMEA: What’s the Difference?

Any new product consists of several development stages, one of which is identifying and fixing potential problems. Whether you’re using lean or other quality processes in your enterprise, you must have an excellent qualitative risk assessment process.

The FMEA and FMECA processes help to manage potential risks likely to cause quality defects. But what makes the two different?

Read on to find out the FMEA vs. FMECA process comparison.

What Is FMEA?

FMEA stands for “Failure Modes and Effects Analysis.” It is a step-by-step method for finding mistakes or flaws in the way things are made, designed, or put together, as well as in the products or services themselves.

Failure modes are the mechanisms by which failures occur. Failures can lead to client dissatisfaction and fewer sales. The effects analysis investigates the causes or consequences of failure. FMEA strives to prevent or mitigate failures, starting with the most critical.

To avoid failures, FMEA is employed throughout the design stage. It is then used in the controlling process, both before and throughout the continuous operation of the process. FMEA should start at the beginning of the design process and continue for the whole life of the product or service.

What Is FMECA?

FMECA is an upgraded form of FMEA that adds a criticality analysis part to chart the failure mode likelihood against impact. FMECA identifies system failures, their causes, and their impacts. With criticality, FMECA may locate and focus on design areas of concern.

This approach examines possible problems in greater depth than FMEA and produces more reliable results. It finds the most serious mistakes based on how likely they are to happen and how bad they are if they do.

FMECA is simply FMEA with Criticality Analysis added in because there are numerous variations of FMEA such as: Conceptual or Functional FMEAs, Design FMEAs, and Process FMEAs.


The terms “FMEA” and “FMECA” are often used interchangeably, and some people even consider them to be the same. However, there is a distinction between the two methodologies.

FMEA lacked intensity, frequency, and recognition rankings. Hence FMECA’s criticality matrix was needed to assess FMEA hazards.

FMEA figures out how a product or process could fail and what would happen if it did. Criticality Analysis or FMECA ranks these failure modes by how important they are and by looking at how often they fail.

To do FMECA, you must first do FMEA and then do a critical analysis. These processes are linked and help each other out, which makes it easier to analyze.

To help people learn how to do useful Failure Modes, Effects, and Criticality Analysis based on supportability, Andromeda Systems, Inc. offers SFMECA Training Course. This program talks about how FMECA helps supportability analysis and how to find failure modes so that analysis is accurate and efficient.

Produce High-Quality Products and Services

The expectations of today’s consumers continue to rise to new heights. Security, usability, and performance are the highest considerations.

FMEA and FMECA can help you produce high-quality products and services. Hospital tomographs and ultrasound machines can undergo FMEA and FMECA. These strategies also help banks detect ATM faults.

These strategies enhance standards by making products more durable, reliable, and secure. They save resources on developing products and legal action.

Keep reading our blog to learn more about quality and development issues!

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