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FMEA is a structured procedure for identifying and preventing as many potential failure modes as possible. It is a powerful technique for eliminating costly failures in the manufacture of a product by ensuring critical issues are addressed before costly actions are taken. This training is designed to show the participants how one can use the FMEA to help identify the activities that are potential risks in the introduction of a new product, process or service. In addition, this training is designed to help eliminate problems from current designs, processes or services.

Course objectives:

At the end of this workshop, participant would be able to

▪ Understand the functioning of FMEA, its usage and application
▪ Able to link FMEA controls and update control plan
▪ Able to recognize and evaluate potential failure works and assign causes to them
▪ List actions to reduce the chances of a potential failure mode, and
▪ Tap teams knowledge, experiences and ideas

Who Should Attend:  This course is designed for individuals from engineering, quality, purchasing, manufacturing or marketing who might participate in the development of FMEA.

Course Content:

Session 1.0: Introduction to FMEA

-          The FMEA Process Within a System of Advanced Product Quality Planning

-          FMEA & the Overall Improvement Strategy

-          Interrelationships between System, Design and Process FMEA

-          QFD & Its Interrelationship to Process FMEA

-          The Benefits of  FMEA

Session 2.0: The FMEA Process

-          FMEA : A Team Effort

-          Information Sources for Use in the  Process FMEA

-          Mapping the Process Using a Flow Diagram

-          Failure Mode Brainstorming and Evaluation

-          Using the Cause and Effect Diagram to Analyze Failure Modes

-          Identification of Current Controls

-          Estimating the:

-          Severity of the Potential Effects

-          Occurrence Rate of Cause/Failure Mode Mechanism

-          Capability of Manufacturing Process Controls to Detect the Failure Mode

-          Documenting the FMEA

Session 3.0: Using FMEA to Improve the Process

-          Prioritizing Failure Modes

-          Developing Recommended Actions

-          Using Process FMEA to Drive:

-          Product Design Changes

-          Manufacturing Process Changes

-          Pre-Launch Control Plan

-          Production Control Plan

-          The Process FMEA as a Living Document

Session 4.0: Writing Control Plans from FMEAs

-          Introduction to Control Plans

-          The Relationship Between:

-          Causes of Process FMEA Failure Modes & Process Parameters

-          Process FMEA Failure Modes & Product Characteristics

-          Using the QFD Process Planning Matrix to Prioritize Controls

-          The Control Plan as a Living Document

Course Duration: 2 days

Training Methodology: Classroom lectures complemented with group case studies and assignments.