{"id":11622,"date":"2026-04-22T14:54:49","date_gmt":"2026-04-22T19:54:49","guid":{"rendered":"https:\/\/plexusintl.com\/us\/?page_id=11622"},"modified":"2026-04-23T13:49:11","modified_gmt":"2026-04-23T18:49:11","slug":"enabling-lessons-learned-read-across-with-fmea","status":"publish","type":"page","link":"https:\/\/plexusintl.com\/us\/blog\/enabling-lessons-learned-read-across-with-fmea\/","title":{"rendered":"Enabling Lessons Learned Read Across with FMEA"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-page\" data-elementor-id=\"11622\" class=\"elementor elementor-11622\" data-elementor-post-type=\"page\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-57fc58ac elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"57fc58ac\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-66 elementor-top-column elementor-element elementor-element-5538bb77\" data-id=\"5538bb77\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-ad0cf17 elementor-widget elementor-widget-theme-post-title elementor-page-title elementor-widget-heading\" data-id=\"ad0cf17\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"theme-post-title.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">Enabling Lessons Learned Read Across with FMEA<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-86798a4 elementor-widget elementor-widget-heading\" data-id=\"86798a4\" 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\">Unleashing the power of your FMEA<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-593659ff elementor-widget elementor-widget-post-info\" data-id=\"593659ff\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"post-info.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<ul class=\"elementor-inline-items elementor-icon-list-items elementor-post-info\">\n\t\t\t\t\t\t\t\t<li class=\"elementor-icon-list-item elementor-repeater-item-8292eda elementor-inline-item\" itemprop=\"datePublished\">\n\t\t\t\t\t\t<a href=\"https:\/\/plexusintl.com\/us\/2026\/04\/22\/\">\n\t\t\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-icon\">\n\t\t\t\t\t\t\t\t<i aria-hidden=\"true\" class=\"fas fa-calendar\"><\/i>\t\t\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<span class=\"elementor-icon-list-text elementor-post-info__item elementor-post-info__item--type-date\">\n\t\t\t\t\t\t\t\t\t\t<time>April 22, 2026<\/time>\t\t\t\t\t<\/span>\n\t\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t<\/li>\n\t\t\t\t<\/ul>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-36a748f3 elementor-widget elementor-widget-text-editor\" data-id=\"36a748f3\" 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>Most lessons learned systems fail for a simple reason: they rely on people to remember, communicate, and follow through. Here is how it usually goes: you become aware of a lesson learned and are tasked with sharing it across different areas, manufacturing lines, and facilities in your organization.\u00a0 You probably schedule some meetings, send a few emails, document the lesson learned somewhere in a spread sheet or database, issue a quality alert, and hope that someone follows through.<\/p><p>You rely entirely on the people you talked to or emailed maybe once or twice, to follow through with the read-across; and when a system depends on people, its outcome cannot be predicted.<\/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-ceb485d elementor-widget elementor-widget-heading\" data-id=\"ceb485d\" 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<h3 class=\"elementor-heading-title elementor-size-default\">An overlooked strength of FMEA<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-29f2ded elementor-widget elementor-widget-text-editor\" data-id=\"29f2ded\" 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 good news is, your organization already has the processes and tools in place you need to ensure robust \u201cread across\u201d or <em>Yokoten<\/em>. They may need improvement or adjustments, but they exist.\u00a0 I\u2019m referring to the Failure Modes and Effects Analysis tool and the Internal Audit Program \u2013 specifically, manufacturing process audits.<\/p><p>A Failure Mode and Effects Analysis (FMEA) is a team-oriented analysis to evaluate the potential risk of failures, their causes and effects.\u00a0 This analysis helps determine and document existing or recommended prevention and detection controls to lower that risk. There are many known and stated benefits of FMEAs.\u00a0 One of the most valuable and often overlooked is how strongly they enable the read-across of lessons learned systematically.<\/p><p>When structured properly, your FMEAs in combination with your internal audit program can provide you with the identification, documentation, communication, and even verification of read across, of a lesson learned.\u00a0 There is no need to add or create a separate process for lessons learned, or a database people may or may not use, or extra meetings and increased follow-ups just to ensure read across.\u00a0 Under this scenario, you will be taking advantage of your established and required quality management system processes to accomplish read across.<\/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-3f68d3c elementor-widget elementor-widget-heading\" data-id=\"3f68d3c\" 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<h3 class=\"elementor-heading-title elementor-size-default\">Building a hierarchical FMEA system<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2149e7e elementor-widget elementor-widget-text-editor\" data-id=\"2149e7e\" 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 this to work, you will need to structure your failure modes and effects analyses in a hierarchical manner, starting by creating a <em><u>foundation<\/u><\/em> FMEA atop of the hierarchy.\u00a0 Then, you set-up another FMEA \u2013 a <em><u>family<\/u><\/em> FMEA as a child to that foundation FMEA.\u00a0 The family FMEA will \u201cinherit\u201d (i.e. copy) all content of the foundation FMEA and will contain additional information specific to a family of products.\u00a0 Finally, you will create a <em><u>product<\/u><\/em> FMEA (if required), under the family FMEA and as a grandchild to the foundation FMEA.\u00a0 The product FMEA will inherit all content from the family FMEA, and therefore the foundation, and will contain additional information specific to that product.\u00a0<\/p><p>Although these are optional practices in the AIAG|VDA FMEA Handbook 1<sup>st<\/sup> (that may be required by some customers), the aforementioned structure, illustrated below, is key for the FMEAs to facilitate read across.<\/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-29fb3c6 elementor-widget elementor-widget-image\" data-id=\"29fb3c6\" 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<figure class=\"wp-caption\">\n\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"626\" height=\"253\" src=\"https:\/\/us-wp-cdn.plexusintl.com\/wp-content\/uploads\/2026\/04\/22150903\/Figure-1-Example-of-a-FMEA-Hierarchical-Structure.png\" class=\"attachment-large size-large wp-image-11625\" alt=\"Hierarchical diagram showing three FMEA levels: Foundation FMEA at the top captures enterprise-level knowledge for Product Line 1; Family FMEA in the middle adapts that knowledge to customer application groups (Customer 1 and Customer 2 applications of Product Line 1); and Product\/Part-number FMEA at the bottom applies knowledge to specific parts (P\/N 1234-AB-567, P\/N 1234-AB-568 under Customer 1, and P\/N 9AB-01 under Customer 2).\" srcset=\"https:\/\/us-wp-cdn.plexusintl.com\/wp-content\/uploads\/2026\/04\/22150903\/Figure-1-Example-of-a-FMEA-Hierarchical-Structure.png 626w, https:\/\/us-wp-cdn.plexusintl.com\/wp-content\/uploads\/2026\/04\/22150903\/Figure-1-Example-of-a-FMEA-Hierarchical-Structure-300x121.png 300w\" sizes=\"(max-width: 626px) 100vw, 626px\" \/>\t\t\t\t\t\t\t\t\t\t\t<figcaption class=\"widget-image-caption wp-caption-text\">Figure 1: Example of a FMEA hierarchical structure<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\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-b0aa967 elementor-widget elementor-widget-text-editor\" data-id=\"b0aa967\" 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>Defining what your foundations and families FMEA are going to be is highly dependent on your organization, its products and processes, and the tool or software you are using in your FMEA process.\u00a0 As a general rule, a foundation FMEA should be generic enough to capture product and process knowledge accumulated throughout the product\u2019s lifecycle. Try to keep the number of foundations FMEAs manageable so they can be easy to maintain.<\/p><p>Examples of foundation Design FMEAs could include: a function or a generic product design (i.e. a half-shaft).\u00a0 Example for a family DFMEA could be a half shaft with a specific type of joint and tube type\/length.\u00a0 Design foundations can also be defined for different levels of integration in an assembly, sub-assembly or a component, if they add value to your FMEA process.\u00a0 Examples of a foundation for process FMEA could be an assembly process\/line, a work center, an operation, or even an activity\/task.\u00a0 Whichever way your foundations are defined, they should be able to be used as the starting point for all new families and part number-specific FMEAs, therefore ensuring that all accumulated knowledge (i.e. lessons learned) is transferred to new products or programs.<\/p><p>Now that you understand and have your FMEAs structured this way, let\u2019s walk through how enabling read across works.\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-e366461 elementor-widget elementor-widget-heading\" data-id=\"e366461\" 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<h3 class=\"elementor-heading-title elementor-size-default\">How lessons learned propagate<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-943a948 elementor-widget elementor-widget-text-editor\" data-id=\"943a948\" 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 lesson learned is identified (from structured problem solving, warranty investigations, new knowledge on new programs, continuous improvements projects, etc.), you will review it and determine the scope of the read across. \u00a0Let us assume that we recently learned that a part escaped our process without a key machining feature. The team later determined that it was caused by a worn-out tool and implemented a tool cycle counter with limits to preventively change the tool before it wears out, and a camera to detect the presence of the missed feature.\u00a0 Because this condition could potentially occur anywhere this product is machined, the team documented both actions in the optimization section (step 6) of the foundation process FMEA for that product line.<\/p><p>Because of the hierarchical structure set up the action in step 6 will be added to all children (family) and grandchildren (product) FMEA, triggering actions to evaluate and implement the new controls or similar controls for the identified lesson learned anywhere the product is machined in the organization.<\/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-2a7a05d elementor-widget elementor-widget-heading\" data-id=\"2a7a05d\" 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<h3 class=\"elementor-heading-title elementor-size-default\">Verifying read across with already planned audits<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-5e8f46c elementor-widget elementor-widget-text-editor\" data-id=\"5e8f46c\" 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 time, you will need to verify the implementation of these actions to confirm read across. This is where your internal audit program can help.\u00a0 A Quality Management System requires internal audits, and particularly an Automotive QMS requires organizations to perform manufacturing process audits. If you plan the process audit to be performed utilizing reverse process FMEA, you can verify read across, perform the process audit, and perform reverse process FMEA all concurrently.\u00a0 This avoids duplicating efforts (increases efficiency), plus ensures a more effective and robust approach to the verification of read across and a value-added process audit.<\/p><p>Sustaining FMEAs and ensuring read across are two distinct areas that can challenge any QMS. Keeping up with these two requirements often lead to overly complex systems that are difficult to maintain, hard to follow, and ultimately discourage consistent use. By leveraging and enhancing the processes and requirements of your QMS in innovative ways, organizations can reduce complexity, save time, and create a more effective and predictable system for the lessons learned read across.<\/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<\/div>\n\t\t\t\t<div class=\"elementor-column elementor-col-33 elementor-top-column elementor-element elementor-element-a403cce\" data-id=\"a403cce\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-c694ee elementor-widget elementor-widget-text-editor\" data-id=\"c694ee\" 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<h3>Stay Ahead of the Curve<\/h3><p>Subscribe to our newsletter.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div 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elementor-top-column elementor-element elementor-element-07b0ba8\" data-id=\"07b0ba8\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-9b0e4fe elementor-cta--skin-cover elementor-cta--valign-top elementor-bg-transform elementor-bg-transform-move-down elementor-animated-content elementor-widget elementor-widget-call-to-action\" data-id=\"9b0e4fe\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"call-to-action.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<a class=\"elementor-cta\" href=\"https:\/\/www.aiag.org\/training-and-resources\/webinars\/details\/E26FMEAWEB?utm_source=Plexus&#038;utm_medium=Marketing&#038;utm_campaign=FMEA_Webinar\" rel=\"noopener\">\n\t\t\t\t\t<div class=\"elementor-cta__bg-wrapper\">\n\t\t\t\t<div class=\"elementor-cta__bg elementor-bg\" style=\"background-image: url();\" role=\"img\" aria-label=\"\"><\/div>\n\t\t\t\t<div class=\"elementor-cta__bg-overlay\"><\/div>\n\t\t\t<\/div>\n\t\t\t\t\t\t\t<div class=\"elementor-cta__content\">\n\t\t\t\t\t\t\t\t\t<div class=\"elementor-content-item elementor-cta__content-item elementor-icon-wrapper elementor-cta__icon elementor-view-default elementor-animated-item--grow\">\n\t\t\t\t\t\t<div class=\"elementor-icon\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t<h2 class=\"elementor-cta__title elementor-cta__content-item elementor-content-item elementor-animated-item--grow\">\n\t\t\t\t\t\tTune into the Webinar\t\t\t\t\t<\/h2>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t<div class=\"elementor-cta__description elementor-cta__content-item elementor-content-item elementor-animated-item--grow\">\n\t\t\t\t\t\tIn this session, Wanda I. Col\u00f3n-Rivera, Director of Global Quality &amp; Global QMS Internal Auditor at Neapco, walks through a real FMEA transformation journey \u2014 sharing practical lessons learned and how to turn challenges into lasting quality improvements.\t\t\t\t\t<\/div>\n\t\t\t\t\n\t\t\t\t\t\t\t\t\t<div class=\"elementor-cta__button-wrapper elementor-cta__content-item elementor-content-item elementor-animated-item--grow\">\n\t\t\t\t\t<span class=\"elementor-cta__button elementor-button elementor-size-\">\n\t\t\t\t\t\tRegister Today\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-76f05cd elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"76f05cd\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-5c01ee5\" data-id=\"5c01ee5\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-4342317 elementor-widget elementor-widget-spacer\" data-id=\"4342317\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"spacer.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-spacer\">\n\t\t\t<div class=\"elementor-spacer-inner\"><\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>Active<\/p>\n","protected":false},"author":11,"featured_media":0,"parent":327,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":"","_wp_rev_ctl_limit":""},"class_list":["post-11622","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/pages\/11622","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/users\/11"}],"replies":[{"embeddable":true,"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/comments?post=11622"}],"version-history":[{"count":1,"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/pages\/11622\/revisions"}],"predecessor-version":[{"id":11641,"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/pages\/11622\/revisions\/11641"}],"up":[{"embeddable":true,"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/pages\/327"}],"wp:attachment":[{"href":"https:\/\/plexusintl.com\/us\/wp-json\/wp\/v2\/media?parent=11622"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}