Objective: to assess potential failures in the care process with orthotics, prosthetics and special materials in a high-complexity hospital. Method: an intervention study conducted from March to October 2013. This process was assessed with the Failure Mode and Effects Analysis (FMEA) service tool. The data were analysed according to the risk and the corrective measures were defined. Results: no failure was classified as high risk and the corrective measures indicated as low and moderate risk

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... the following improvement initiatives suggested: standardize the material records in the information system; create a specific form to require materials; hire specialized technical personnel and create a continuous education program. Conclusion: all the suggested initiatives were implemented and helped to reduce the assistance risks for patients due to failures in this process. The actions increase safety levels and provide higher quality of service.