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Failure Mode Effect Analysis (FMEA)
Introduction
 | Do you have products or processes where failure is costly
or critical? |
| How do you reduce the risks of failure? |
| How do you ensure reliability of product and processes? |
| What design controls do you have to minimize the chances of
failure? |
| Are 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:
| Understand the use of FMEA for products and processes. |
| Construct FMEA tables for products and processes.
 | Calculate Risk Priority Numbers |
| Analyze risk at any stages of the design or production
process |
| Take action to reduce failures |
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| Document the FMEA process and generate the Control Plan. |
| Know the importance of setting the right Control plan in
ensuring quality and process capability. |
| Ensure product and process quality and reliability in a
proactive manner. |
| Manage 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
| Wasted effort in reengineering |
| Global competition |
| Quality and reliability of products |
| Risks and reducing risks |
FMEA Methodology
| Approaches in managing a process |
| Risk analysis |
| Process flow charts |
| Design and Process FMEA |
| Fault tree analysis |
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Tools for FMEA
| Identifying root causes |
| Problem Solving Techniques |
| Analyzing and writing procedures |
| Poka Yoke methods |
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| Day 2 (AM) |
Day 2 (PM) |
Design FMEA
| Identifying of Failure Modes |
| Measures of Probability, Severity and Detection |
| Design Controls |
| Reducing Risks, Example |
Process FMEA
| Identifying of Failure Modes |
| Measures of Probability, Severity and Detection |
| Design Controls |
| Reducing Risks, Example |
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FMEA and other tools
| Quality Function Deployment (QFD) |
| Statistical Process Control (SPC) |
| Design of Experiments (DOE) |
| Example of QFD, SPC and DOE |
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| Day 3 (AM) |
Day 3 (PM) |
FMEA to Control Plan
| Example of Control Plan |
| Audit Procedures |
| Writing Procedures |
| Exercise |
| Discussion |
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Discussion
| FMEA Team formation |
| Managing teams |
| Teamwork, maintaining team morale |
| Conclusion |
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