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Design Failure Mode and Effects Analysis

  • About the Course
  • Certification Body
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Overview of the course:

It’s rightly said that prevention is better than cure! The Failure Mode and Effects Analysis (FMEA) was developed in the aerospace industry in 1960 as the systematic method through which designs and weaknesses of processes could be identified and investigated. FMEA training is for those individuals who are involved in designing of the products, processes or services with specification in improving the business or management of process improvement. Failure Mode and Effects Analysis (FMEA) techniques have been around for over 40 years. In recent years, use of FMEAs has gained popularity as a quality improvement tool.

This interest is in large part due to the automotive industry and specifically its IAFT 16949 supplier requirements. Other major industries, including aerospace, medical products and electronics are also using FMEA techniques as part of their improvement and risk assessment strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics. FMEA studies can yield significant savings for a company as well as reduce the potential liability of a process or product that does not perform as promised.

Learning Outcome:

By participating in this On Demand course, you will be able to:

  • Describe the FMEA history, terms, standards and types
  • State the benefits and advantages of using an FMEA
  • Describe the composition and responsibilities of an FMEA team
  • Explain when an FMEA is needed and the timing involved
  • Describe the basic information and inputs required in each column of an FMEA form
  • Explain the purpose of conducting an FMEA.
  • Explain the methodology of the FMEA process.
  • Assemble an FMEA team.
  • Define the scope of a DFMEA.
  • Work though each steps of conducting a DFMEA.
  • Use the FMEA Analysis Worksheet to document the results of the study.
  • Customize the Severity, Occurrence and Detection Ranking Scales.
  • Use the results of a DFMEA to trigger continuous improvement.

Who needs the course?

This course is specially designed for:

  • Product developers involved in developing new product introduction strategies and those concerned with ‘time-to-market’.
  • Manufacturing and engineering managers, who need to improve manufacturing capability, predict initial product yield and improve cross-functional technical communications.
  • Design engineers responsible for new product design and introduction that need to improve customer definition and manufacturing feedback.
  • Quality/Reliability managers and engineers who want to facilitate an awareness and application of these tools within their organization.
  • Process engineers who will be involved in formulating the manufacturing Control Plan.
Design Failure Mode and Effects Analysis

FMEA Training Detailed Course Content

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
         o The three path model
  • Team structure and rules for efficiency
         o Team membership for best results

FMEA Linkage and Collaboration

  • The link between Design and Process FMEA
       o Special Characteristics (Critical and Significant)
       o Collaborative Product (Process) Development (CPD) on Special Characteristics
       o Special Characteristics as inputs to PFMEA
       o Tolerance Design and Process Capability Estimation
  • What is Risk?
       o Criticality (Severity X Occurrence)
       o Risk Priority Number (RPN) and its use
       o 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)
      o Interface analysis / Boundary Diagram
      o Parameter Diagram

Methodology and hands on experience

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

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

Practical Application of PFMEA

Pre-work:

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

Methodology and hands on experience

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

For more information on DFMEA, click here.

To know more about other courses in Engineering Academy, click here.

About Certification and Awarding Body

KHDA Certificate:

Course completion certificate attested by KHDA(Knowledge and Human Development Authority, UAE)

The Knowledge and Human Development Authority (KHDA) is responsible for the growth and quality of private education in Dubai. We support schools, universities, parents, students, educators, investors and government partners to create a high quality education sector focused on happiness and wellbeing.

Title: Design Failure Mode and Effects Analysis

For application process, please contact us.

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