Failure Mode And Effects Analysis (FMEA)

This workshop can be structured as introductory workshop or as a three-day hands-on workshop. The objective of the longer workshop is to create a Design Failure Modes and Effects Analysis (DFMEA) or a Process Failure Modes and Effects Analsysis (PFMEA).

Although completion may not be possible due to the complexity of a product, significant progress should be made to allow completion by group at later time. The workshop can further be oriented toward hardware or software products.

The workshop will cover the following:

1. Introduction to FMEA

•             Relationship to Design for Six Sigma (DFSS), Other Quality Frameworks, and Reliability

•             FMEA Definition & Purpose

o             Design FMEA

o             Process FMEA

•             Overview of the FMEA Worksheet

•             Benefits of FMEA’s

•             Inputs and Outputs to FMEA

2. Evaluating Potential Failures – The FMEA Process

•             Failure Mode Definition and Categories

•             Identifying Potential Failure Modes

•             Examples of Failure Modes – Design and Process

•             Determining Effects

•             Examples of Effects

•             Rating Severity

•             Severity Rating Definition and Tables

•             Determining Causes

•             Methods and Guidelines for Determining Causes

•             Rating Occurences

•             Occurrence Rating Definition and Tables

•             Identifying Controls

•             Types of Design and Process Controls

•             Rating Detection

•             Design and Process Detection Rating Tables

•             Assessing Risk

•             The Risk Profile Number (RPN)

•             Exercises to Perform FMEA Process Steps

3. Responding to Potential Failures – The FMEA Process

•             Developing an Action Plan

•             Assigning Responsibility

•             Follow-Up and Re-Evaluation

•             Managing Design Risk for a Project

4. Related Methodologies

•             Fault Tree Analysis

•             Mistake Proofing

•             Production Control Plans

5. Making it Happen

•             Managing FMEA’s

•             Important FMEA Keys to Success

•             Institutionalizing FMEA in your Organization

6. Optional FMEA Exercise – Analyze an Actual Company Product or Process