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
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