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FAILURE MODE EFFECT ANALYSIS (FMEA)

INTRODUCTION

bulletDo you have products or processes where failure is costly or critical?
bulletHow do you reduce the risks of failure?
bulletHow do you ensure reliability of product and processes?
bulletWhat design controls do you have to minimize the chances of failure?
bulletAre your engineers trained to systematically reduce the chances of failure?

Failure mode effects analysis (FMEA) provides a disciplined procedure which enables a design or manufacturing engineer to anticipate and rectify potential failures in a design or manufacturing process. FMEA is an integral part of any Quality Management System (e.g. ISO 9000, QS 9000, etc.). This course enables the delegates to conduct FMEA on Design and Processes to reduce producer’s and consumer’s risks. Many examples help the delegates to understand and use the course effectively.

BENEFITS OF ATTENDING THE COURSE

The course enables the delegates to:
bulletUnderstand the use of FMEA for products and processes.
bulletConstruct FMEA tables for products and processes.
bulletCalculate Risk Priority Numbers
bulletAnalyze risk at any stages of the design or production process
bulletTake action to reduce failures
bulletDocument the FMEA process and generate the Control Plan.
bulletKnow the importance of setting the right Control plan in ensuring quality and process capability.
bulletEnsure product and process quality and reliability in a proactive manner.
bulletManage and facilitate cross functional teams.

WHO SHOULD ATTEND

FMEA is used to reduce the risk of product or  process failures proactively. It will be most appropriate for those involved in Quality, Design and Development, Manufacturing, Production and Service. Teams are encouraged to attend for maximum benefit.

BRIEF COURSE OUTLINE

Day 1 AM Day 1 PM
Introduction
bulletWasted effort in reengineering
bulletGlobal competition
bulletQuality and reliability of products
bulletRisks and reducing risks

FMEA Methodology

bulletApproaches in managing a process
bulletRisk analysis
bulletProcess flow charts
bulletDesign and Process FMEA
bulletFault tree analysis
Tools for FMEA
bulletIdentifying root causes
bulletProblem Solving Techniques
bulletAnalyzing and writing procedures
bulletPoka Yoke methods

Design FMEA

bulletIdentifying of Failure Modes
bulletMeasures of Probability, Severity and Detection
bulletDesign Controls
bulletReducing Risks, Example
Day 2 AM Day 2 PM
Process FMEA
bulletIdentifying of Failure Modes
bulletMeasures of Probability, Severity and Detection
bulletDesign Controls
bulletReducing Risks, Example

FMEA to Control Plan

bulletExample of Control Plan
bulletAudit Procedures
bulletWriting Procedures
bulletExercise
bulletDiscussion
FMEA and other tools
bulletQuality Function Deployment (QFD)
bulletStatistical Process Control (SPC)
bulletDesign of Experiments (DOE)
bulletExample of QFD, SPC and DOE

Discussion 

bulletFMEA Team formation
bulletManaging teams
bulletTeamwork, maintaining team morale
bulletConclusion

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Copyright © 2002 Institute of Quality Malaysia. All rights reserved.
Last modified: 11/13/03.