MTBF & FMEA Analysis
Identify, Quantify, Improve Reliability
MTBF & FMEA Analysis automatically calculates Mean Time Between Failures and structures Failure Mode and Effects Analysis using your historical maintenance and failure data.
Instead of manually compiling breakdown history, filtering spreadsheets, and debating assumptions, Nexphase delivers a structured reliability baseline and risk framework in hours.
Each output includes:
Calculated MTBF by asset, component, and failure mode
Failure frequency and trend analysis over time
Structured FMEA tables with ranked failure modes, causes, and consequences
Risk prioritisation to focus effort where it delivers the greatest reliability uplift
Identification of high-risk and repeat-failure components
Clear visual summaries suitable for engineering and executive review
Overview of the MTBF Analysis function within Nexphase
From reliability measurement to risk-based improvement planning, delivered in a single, structured output.
“Most sites have the data. They just don’t have the clarity. MTBF and FMEA Analysis turns years of breakdown history into something reliability engineers can act on.”
How it Works
Extracts and cleans historical data
Ingests work order history, breakdown records, and maintenance logs, standardising inconsistent terminology and incomplete entries.
Identifies failure events
Separates corrective failures from planned work to ensure accurate MTBF calculations and credible failure datasets.
Calculates reliability performance
Computes asset-level and component-level MTBF across equipment hierarchies, revealing reliability trends beyond surface-level metrics.
Structures failure modes and risk
Groups failures into defined modes, mapping causes and consequences to build a structured FMEA with risk ranking.
Highlights repeat and systemic issues
Presents findings in a clear, prioritised format so teams can focus on the assets with the greatest reliability and cost impact.
Structures results for action
Presents reliability metrics and prioritised risk outputs in a clear format, enabling engineering teams to focus on the highest impact improvements.
Key Benefits
Establishes a defensible reliability baseline across assets and components
Identifies recurring and high-risk failure modes before they escalate
Prioritises engineering effort using structured risk ranking, not opinion
Supports data-driven optimisation of maintenance strategies and intervals
Reduces unplanned downtime, production losses, and reactive workload
Guides design improvements and maintenance task refinement based on real data
Understand where your failures are coming from, and how to extend time between them.
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