Failure Mode and Effect Analysis ( FMEA )

Objective

At the end of this Training Programme, participants will be able to, among others:

1. Understand the purpose and benefits of FMEA

2. Understand the FMEA Methodology

3. Create detail Process Mapping

4. Construct Cause & Effect Matrix

5. Create an FMEA by applying the methodology and process steps using a    case study

6. Understand the application of FMEA supporting RCA, Prevention and    Detection tools


The Model:

1. Process Selection Process Mapping

2. Cause & Effect Matrix

3. Process FMEA

4. Control Plans


Course content

1. FMEA Overview

-  History of FMEA
-  What is FMEA?
-  FMEA Model
-  FMEA link to problem prevention
-  Benefits of FMEA
-  Types of FMEA – design, process, equipment
-  FMEA in product  life cycle
-  Roles and responsibilities
-  Steps in filling up FMEA template
-  FMEA Process Steps and Flow

2. Prepare FMEA

-  Define Scope
-  Define Objectives and Success Criteria
-  Define Team
-  Review FMEA Process
-  Gather Relevant Information
-  Prepare Preliminary FMEA
-  Example – marking process

3. Develop FMEA

-  Define Unit Process flow Steps
-  List Potential Failure Modes
-  List Potential Failure Effects

4. Assign Severity Rating

-  Severity overview/guideline
-  Relationship of failure/effect/cause
-  Occurrence guideline
-  Detection overview/guideline
-  RPN guideline

5. Act on FMEA Results

-  Prioritize Failure Mode
-  Determine recommended action
-  Assign owner(s) to action
-  Data collection
-  Revise FMEA

6. FMEA deployment & Follow-up

-  RPN guidelines
-  FMEA and criticality
-  When to revise FMEA?


Selecting and Developing an In-House Process FMEA:

1. Form a team, with three to four groups

2. Select appropriate critical process

3. Developing a Process Mapping

4. Developing a Cause and Effect Matrix

5. Developing a Preliminary FMEA

6. Focusing on High RPN Numbers

7. Preparing Final FMEA and Reporting


Understanding and application of supporting RCA, Prevention and Detection tools of FMEA:

1. Ishikawa "Fishbone" Diagram

2. Sentencing Technique

3. The Global 8D Problem Solving Approach

4. Flowcharts & Process Mapping

5. Basic Anova (Basic DOE)

6. Statistical Process Control

7. Poka-Yoke (Mistake-Proofing)

8. Control Plan

9. FMEA Software

10.5 Whys Techniques

11.Normality Test

12.Histograms

13.Pareto Charts

14.Basic Statistics

15.Cause & Effect Matrix


Target Audience

1. Managers/QA Engineers/Technicians/supervisors/QA staffs who wish to  apply FMEA to proactively manage the operation issues or abnormalities to stay competitive in the market by using this systematic, scientific approach

2. All Excel Template and Tools are given free for this session

3. All participants are encourage to have computers during trainings