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FMECA Consulting & Facilitation

FMECA that ends in a loaded maintenance strategy, not a binder

HolisticAM facilitates full FMECA programmes that finish as CMMS-ready maintenance strategies: failure modes, effects, criticality, tasks, frequencies, spares and SAP master data, built by engineers who maintained the assets themselves.

On a P&H 4100XPC shovel fleet, our FMECA-based strategy cut corrective maintenance from 56% to 37% of total maintenance in six months.
Scope an FMECA programme
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✓Enterprise Library: thousands of components with known failure modes
✓Sole ANZ ReliaSoft distributor
✓Facilitators from BHP, Rio Tinto, Alcoa and MMG operations
The capability test

Most criticality analyses die in the workshop room

Ask any provider one question: what happens to the worksheet after the last session? If the answer is a report, the analysis will sit on a shelf while the plant keeps failing the same way. A FMECA earns its keep only when every failure mode becomes a task, a frequency, a spare and a work instruction loaded into your CMMS.

HolisticAM runs the workshop and builds what comes after it: the FMECA-based strategy, the service sheets, the CMMS master data and the assurance that it landed. Our Enterprise Library holds thousands of components with known functions and failure modes, so workshops start from a proven base case instead of a blank sheet and your people spend their time on what makes your site different.

New to the method? Read the plain-English explainer: What is FMECA? For the full method, see the definitive guide.

What it covers

From criticality shortlist to loaded strategy

✓

FMECA workshops, facilitated

Experienced facilitators lead cross-functional teams onsite or remote. Your people own the analysis; we keep it honest and moving.

✓

Library-accelerated analysis

The Enterprise Library base case for your equipment class, tuned to your site's operating context, duty and history.

✓

Maintenance strategy build

Failure modes and criticality become tasks, frequencies and trades: a risk-based strategy your planners can schedule.

✓

CMMS / ERP master data

Task lists, maintenance items, plans and BOM inputs delivered load-ready for your CMMS or ERP. We build most often for SAP and Pronto.

✓

ReliaSoft XFMEA

As sole ANZ ReliaSoft distributor we run and supply XFMEA, so your FMECAs become a living, searchable library rather than one-off spreadsheets.

✓

Training and handover

FMECA training and mentoring for your engineers and service providers, so the capability stays when we leave.

FMECA in numbers

Programmes that changed the maintenance mix

56% → 37%
Corrective maintenance share, six months after strategy implementation (P&H 4100XPC fleet)
8
RCM and CHAZOP studies delivered for ANSTO's Synchrotron beam lines
100+
Maintainable units covered in one FMECA for DoT Victoria's road network
1000s
Components with known failure modes in our Enterprise Library

The headline number: on an open-cut coal mine's P&H 4100XPC electric rope shovels, planned-to-corrective ratio sat at 44:56. Six months after our FMECA-based strategy went live, corrective maintenance was 37% of the total.

Proof

Delivered on real fleets and regulated plant

P&H 4100XPC shovels — open-cut coal

Downtime analysis, Weibull life data analysis and FMECA review, delivered as a data-driven strategy with customised service sheets and SAP master data changes. Corrective maintenance fell from 56% to 37% in six months.

Read the case study

ANSTO — Australian Synchrotron

Eight RCM and CHAZOP studies across six new beam lines under the Bright expansion, facilitated remotely in ReliaSoft RCM++, with five reports contributing to ARPANSA regulatory submissions and 30+ ANSTO staff given practical method exposure.

Read the case study

Caterpillar 994K loader — build phase

FMECA maintenance strategy, work instructions and SAP master data requirements developed during the build phase, with in-house training on oil sampling and analysis interpretation. Delivered on time and within budget.

Read the case study

DoT Victoria — road network ITS assets

FMECA training and facilitation for seven service-provider representatives, collating four analyses into one record covering more than 100 maintainable units, with fault codes and a maturity roadmap.

Read the case study

“HolisticAM's HsM Software allowed us to deploy risk based maintenance strategies rapidly. HolisticAM's knowledge transfer of condition monitoring techniques and interpretation ensured our maintenance efficiency increased.”Engineering Manager, mining company (Caterpillar 994K programme)
“The professional approach and product knowledge ensured we achieved the best outcome for the business. We really appreciate the effort and look forward to continuing this relationship with HolisticAM.”Maintenance Manager, open-cut coal mine (P&H 4100XPC programme)
How an engagement starts

A scoped programme, not an open workshop calendar

1

Criticality shortlist

A scoping session against your asset register and failure history. You get a bounded workshop plan: which assets, which teams, how many sessions.

2

Facilitated FMECA

Workshops run onsite or remote from the library base case. Your team contributes operating context; we keep the analysis rigorous and on schedule.

3

Strategy, loaded and assured

Tasks, frequencies, spares inputs and master data delivered CMMS-ready, with training so your team maintains the living library.

Resources

Start with the template, go deep with the guide

Simplified FMEA template (Excel)

The starting worksheet we use to introduce teams to the method, before criticality scoring turns it into a full FMECA. Free, no form.

Download the template

FMEA / FMECA eBook

The full guideline as a PDF, covering the 13-step method across preparation, analysis and action stages.

Claim the free eBook
Questions

FMECA, answered

What about FMEA? Do you run plain FMEAs?
An FMEA identifies failure modes and their effects, then stops. For industrial assets that is where the important decisions begin: which failures actually matter, and what each one justifies spending. That is the criticality analysis, and it is why our customers engage us for the full FMECA rather than an FMEA alone. If you have been asked to arrange an FMEA, a FMECA is almost certainly what your site needs; the comparison is covered in our definitive guide.
How long does a FMECA take?
It depends on asset complexity and how much of the equipment class is already in our Enterprise Library. The scoping step gives you a bounded session plan before you commit; library-accelerated analyses run substantially faster than blank-sheet studies.
Who needs to be in the room?
A cross-functional team of four to six people who know the asset: operations, maintenance and engineering. A criticality analysis done by one individual is the most common way the method fails.
Can workshops run remotely?
Yes. The ANSTO Synchrotron programme ran eight studies remotely without interruption, supporting regulatory submissions throughout.
What do we actually receive?
A risk-based maintenance strategy with tasks, frequencies and trades, customised service sheets, and master data inputs ready to load into your CMMS or ERP, plus the analysis itself in XFMEA if you want a living library.

Underperforming assets and a maintenance plan you don't trust?

Tell us the asset class and the pain. We will show you what a FMECA programme covers, how long it takes, and what it looks like loaded in your CMMS.

Scope an FMECA programme

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