Failure Mode and effect analysis

Course Overview:

To analyze problems comprehensively. Most effective is the Failure Mode and Effect Analysis approach. Through this course, the participants will be able to:

  • Understand the elements of the design and process of the FMEA.
  • Use advanced tools.
  • Create process flow charts and control plans.

Participants will be able to assess risks. Determine the risk levels. And at which a mitigation plan should be executed.

The course will display several case studies. Relevant exercises in an interactive environment. The participants will learn how to build a corrective and control plans to lead the teams in long term sustainment.

Learning Outcome:

The objectives of Quality-One FMEA onsite training courses are to:

  • Perform Product and Process FMEAs
  • Link FMEA to Product Development Process and Advanced Product Quality Planning (APQP)
  • Facilitate a FMEA
  • Participate in the development of a Design and Process FMEA
  • Define risk and determine levels of risk requiring mitigation
  • Set up an effective Cross Functional Team (CFT) required for FMEA Development
  • Efficiently select Severity, Occurrence and Detection rankings
  • Implement a Risk Priority Number (RPN) reduction process
  • Determine design and process special characteristics
  • Understand and demonstrate the links between Design FMEA and Process FMEA
  • Understand the different types of Design and Process FMEAs
  • System
  • Subsystem
  • Component
  • Assembly
  • Manufacturing
  • Create and manage action plans derived from FMEA
  • Manage and store FMEA content for future use
  • Understand links between FMEA and problem solving methods, such as:
  • Eight Disciplines of Problem Solving (8D)
  • 5 Why
  • Root Cause Analysis (RCA)
  • A3
  • Plan Do Check Act (PDCA)
  • Define, Measure, Analyze, Improve, and Control (DMAIC)
  • Design for Six Sigma (DFSS)
  • Understand links to Control Plan Methodology. Save time and cost that come with sending associates to conferences and seminars at offsite locations.

Why Choose Chools?

Access to:

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• 15,000 top books in abstract forms.
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• 50,000 video libraries.

• 1500 training courses.
• 2.6 million Journals and articles.
• 137 Lean Six Sigma toolkit.
• Leadership assessments.
• Quiz, Exam prep, Q&As, Case-studies.

Course Outline:

FMEA Process Overview

  • Introductions and course objectives
  • The history and purpose of FMEA

FMEA Methodology

  • FMEA in Product Development Process
  • System / subsystem / component FMEA
  • FMEA development methodology
  • The three path model
  • Team structure and rules for efficiency
  • Team membership for best results

FMEA Linkage and Collaboration

  • The link between Design and Process FMEA
  • Special Characteristics (Critical and Significant)
  • Collaborative Product (Process) Development (CPD) on Special Characteristics
  • Special Characteristics as inputs to PFMEA
  • Tolerance Design and Process Capability Estimation
  • What is Risk?
  • Criticality (Severity X Occurrence)
  • Risk Priority Number (RPN) and its use
  • When to take action and developing action plans.

Practical application of the Design FMEA technique
Pre-work:
• Failure Mode Avoidance (FMA)
• Robustness tools (Noise factors to include in the FMEA)
• Interface analysis / Boundary Diagram
• Parameter Diagram

DFMEA Closure
• Design Review integration (Design Review Based on Failure Modes (DRBFM) concepts)
• Test Plan development (Design Verification Plan and Report (DVP&R))
• Revisit RPN Rankings after action completion

Methodology and hands on experience

  • Path 1
  • Item / Functions Requirements / Failure Modes / Effects of Failure / Severity
  • Severity ranking guidelines reviewed with best practices
  • Actions for High Severity (9 / 10)
  • Path 2
  • Causes / Prevention Controls / Occurrence
  • Quality-One ION Technique for Cause development
  • Occurrence ranking Guidelines with Best Practices
  • Actions to eliminate and/or reduce cause probability
  • Special Characteristics definition (Key Dimensions / Features)
  • Error Proofing and Mistake Proofing (Poke Yoke)
  • Path 3
  • Test and verification methods
  • Detection ranking guidelines
  • Actions to improve tests and verification techniques
  • RPN reduction

Practical Application of PFMEA

Pre-work:

  • Failure Mode Avoidance (FMA)
  • Process Flow Chart
  • Characteristic Matrix
  • Lean Value Stream Map (optional)

Methodology and hands on experience

  • Path 1
  • Process Name / Functions Requirements / Failure Modes / Effects of Failure / Severity
  • Severity ranking guidelines review with best practices
  • Actions for High Severity (9 / 10)
  • Path 2
  • Causes / Prevention Controls / Occurrence
  • Ishikawa (6M’s) and Use of Quality-One Matrix for Cause development
  • Human Factors Engineering (Operator Error treatments)
  • Occurrence ranking Guidelines with Best Practices
  • Actions to eliminate and/or reduce cause probability
  • Error Proofing for Human Error
  • Path 3
  • Test and verification methods for Causes and/or Failure Modes
  • Detection ranking guidelines
  • Actions to improve tests and verification techniques

Control Plan Relationships

  • Pre-Launch Control Plan
  • Production Control Plan

PFMEA Revisit FMEA RPN and Re-Rank

Managing FMEAs

  • Family or Baseline FMEA / Legacy
  • FMEA and 8D / RCA Relationship

 

Q&A and Closure

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