Failure Mode and Effects Analysis (FMEA)

  • Delivery Option: Public & On-Site
  • Subject Category: Core Tools
  • Cost: $450
  • Number of Days: 1

Course Summary

QC Training Services’s Failure Mode and Effects Analysis (FMEA) class is an introduction to the FMEA process within an APQP system, its planning, strategy and benefits. Learn the structure and information sources for effective use of FMEA and its correlation to the rest of the AIAG core tools.

Testimonials

“The course offered a great approach to creating FMEAs and help identify risk.” – Jason, MN

“Very good class with a lot of info. Can see things we need to improve at work.” – Travis, MN

“I like the methodology and approach. This course will be very effective once we implement this.” – Ryan, CA

Target Audience

People from quality, manufacturing, engineering, purchasing or marketing will benefit from this Failure Mode and Effects Analysis class, in understanding the cases for when to apply the FMEA process (new design or process, modifications to existing design or process, or use of existing design or process in a new application).

Course Objectives

This program provides a fundamental and practical review of Failure Mode and Effects Analysis. FMEA is an excellent quality tool to use with any quality system. While the general benefits of Process FMEA are similar to those of Design FMEA, the specific benefit is that you will learn to use these powerful tools effectively to improve processes in your organization. Reference the complete Course Description and Agenda for additional details.

Benefits

Participants will learn the general application of the FMEA methodology, which is common to both DFMEA and PFMEA, how to estimate the Severity, Occurrence and Detection rates as well as alternate methods for categorizing and prioritizing failure modes. Your team will become well-versed at developing recommended actions and Control Plans to improve your processes.

Agenda

  • Introduction to FMEA
    • The FMEA process within an APQP system
    • FMEA and Continuous Improvement strategies
    • System, Design and Process FMEA
    • Quality function deployment and FMEA (Process and Design)
    • The benefits of FMEA
  • The FMEA Process
    • FMEA: a team effort
    • Information sources for use with Design and Process FMEA
    • Failure mode brainstorming and evaluation
    • Cause and effect diagrams to analyze failure modes
    • Identification of current controls
    • Estimating the:
    • Severity of the potential effects
    • Occurrence rate of cause/failure mode mechanism
    • Capability of controls to detect the failure mode
    • Calculating the RPN (Risk Priority Number)
    • Documenting the FMEA
  • Using FMEA to Improve the Design and Process
    • Prioritizing failure modes
    • Developing recommended actions
    • Using Design and Process FMEA to drive product design changes, manufacturing process changes and control plans
    • Linking the Corrective and Preventive Action Reports to FMEAs
    • The Design and Process FMEAs as a living documents
  • Writing Control Plans from FMEAs
    • Relationships between causes of process failure modes, process parameters and product characteristics
    • Using the QFD process planning matrix
    • The control plan as a living document
  • Writing Action Plans
    • Graphic-based reaction plans with a process and product control focus and as a data collection tool.
The Automotive Industry Action Group (AIAG) FMEA manual along with the APQP manual are used as the reference materials for this class.