The Complete FMEA Handbook: Mastering Failure Prevention from Basics to AI-Driven Risk Management

Master FMEA in the Age of AI - From Fundamentals to Cutting-Edge Risk Management

Failure Mode and Effects Analysis (FMEA) has been the gold standard for preventing failures in design, manufacturing, and service for decades. But the rules have changed. In today's world of Artificial Intelligence, Industry 4.0, and real-time data, FMEA is evolving into a living, dynamic process - and this book shows you how to master it.

In The Complete FMEA Handbook, best-selling author Mohammed Hamed Ahmed Soliman - known for Practical Guide to FMEA and Risk Assessment Using FMEA - delivers the ultimate, modern reference for engineers, managers, and quality professionals. Building on concepts from Practical Guide to FMEA, this new book offers fresh examples, modern AI applications, and expanded insights for today's engineers. Written in a clear, engaging style and designed for both print and audio formats, this guide works whether you're reading at your desk or listening on the go.

Inside, you'll discover:

• FMEA Fundamentals Made Clear - Step-by-step guidance for DFMEA, PFMEA, and service FMEA.
• Real-World Case Studies - From industrial air compressors to wind turbine systems.
• Service & Office Applications - How to apply FMEA in healthcare, finance, IT, and beyond.
• Modern AI-Driven FMEA - Using digital twins, predictive analytics, and real-time data integration.
• Common Pitfalls and How to Avoid Them - Ensure your FMEA adds value, not just paperwork.
• Practical Tools & Appendices - Rating scales, checklists, and glossary for quick reference.

Whether you're implementing FMEA for the first time or updating your process for the digital era, this handbook equips you with the knowledge and tools to anticipate failures, protect customers, and stay ahead of the competition.

Dr. Mohammed Hamed Ahmed Soliman is an internationally recognized Lean expert, author, and university lecturer. He has published over 100 books and articles on Lean thinking, quality systems, and industrial excellence. He currently teaches Industrial Engineering and Management Systems at the American University in Cairo, an Executive Advisor and a member of the Advisory Committee of the IEOM International Society, and consults for global organizations across manufacturing, public services, and education.

With nearly two decades of academic and professional experience, Dr. Soliman has trained professionals across the Middle East, including engagements with Princess Nourah University in Saudi Arabia and Vale Oman Pelletizing Company. He has designed and delivered over 60 leadership and technical development programs, helping organizations build a culture of continuous improvement and operational excellence.

Earlier in his career, he worked in various industrial sectors including crystal-glass manufacturing, fertilizers, and chemicals, while educating teams on the Toyota Production System. He has led numerous lean transformation projects, delivering measurable results and uncovering substantial cost savings by targeting waste across production and service environments.

His lectures and training materials have reached over 200,000 learners via SlideShare, and his research is ranked among the most downloaded papers on the Social Science Research Network (SSRN) by Elsevier.

Dr. Soliman holds a BSc in Engineering, a master's in Quality Management, and postgraduate degrees in Industrial Engineering and Engineering Management. He also holds certifications in quality, cost, and operations management. He is a member of the Institute of Industrial and Systems Engineers (IISE) and the Society for Engineering and Management Systems (SEMS).

His insights have been featured in SAGE Publications, Industrial Management, Lean Thinking, and other peer-reviewed platforms.