Introduction to Failure Modes & Effects Analysis for Manufacturing Processes, Assembly Processes & Service (Process FMEA)
I.D. # 90033 Duration 1 Day

This seminar introduces the participant to the analytical process in which potential failure modes, failure effects and causes of failure are identified. Criticality and risk analysis concepts are also covered for dealing with the effects of failure. Analysis is used to identify corrective actions that may be used to eliminate failure modes or minimize the effect of failure. Additionally, the analysis may be used to identify controls necessary to prevent failure occurrence. This course covers the AIAG standardized format for FMEA and the succeeding SAE Standard for FMEA, J1739, which is included in the course materials.

There is considerable overlap between this course and I.D.#90034 - Introduction to Failure Modes and Effects Analysis for Product Design (Design FMEA). See course I.D.#92002 - Introduction to Failure Modes & Effects Analysis for Product Design & Manufacturing Process Design (Product & Process FMEA) if you are interested in both Product & Process FMEA.
Learning Objectives
By attending this seminar, you will be able to:
  • List the benefits, requirements and objectives of an FMEA
  • Explain the steps and methodology used to analyze a Process FMEA
  • Compare a variety of tools utilized when performing an FMEA
  • Identify corrective actions or controls and their importance in minimizing or preventing failure occurrence
  • Review the objectives of the SAE Standard for FMEA, J1739
Who Should Attend
This seminar is designed for the manufacturing engineer, process assurance engineer, reliability engineer, test engineer, quality engineer, development engineer, logistics/support engineer and their management or anyone responsible for the design and development of manufacturing, assembly or service processes in the completion of a Process FMEA.
Prerequisites
Individuals attending the seminar should have a basic understanding of the manufacturing/assembly process and design principles.
Seminar Content
  • Introduction & Overview
    • Definition
    • General discussion -- requirements for analysis; uses/objectives of analysis; benefits
    • Timing & relationships -- level of analysis (detail); design FMEA versus process FMEA
  • Performing a Design FMEA & Process FMEA
    • Pre-analysis activities -- determine customer requirements - quality function deployment (QFD); environmental conditions/considerations; determine required functions; develop block diagrams; process flow diagrams
    • Basic analysis methodology -- approach; sequence
    • Criticality/risk analysis (prioritization)
    • Typical forms used & examples
  • Problems Encountered
    • Application
    • Timing
    • Prioritization
  • Fault Tree Analysis as a Support Tool
    • Introduction - approach; FMEA relationship
    • FTA sequence
    • Analysis overview - symbols; examples; workshop
    • Limitations
    • Benefits
  • Application
    • Combined FMEA/FTA examples
    • Detained FMEA examples
    • FMEA/FTA comparisons
  • Using the Results
    • Logistics support analysis (LSA)
    • Failure prevention analysis (MPA)
    • Test planning
  • Other Related Methods/Tools
    • Design review
    • Checklists
    • Lessons learned
    • Design of experiments (DOE)
    • SPC
    • Design for assembly (DFA)
    • Value engineering
    • FMEA software
  • Keys for Successful Implementation
    • Activity as process versus a task
    • Analysis by group/team versus individual -- roles & responsibilities; use of facilitators
  • FMEA & Product Liability
Instructor(s): E. Harold Vannoy
Mr. Vannoy currently operates a consulting business specializing in product design assurance, process design assurance and reliability engineering. He earned a B.S. and M.S. in Electrical Engrg. from the Univ. of Missouri-Rolla; studied probability and statistics at Purdue Univ.; and studied reliability engrg. at the Univ. of Arizona. He is a Registered Professional Engineer in the state of Indiana, a Certified Reliability Engineer and a member of Eta Kappa Nu. He is also a member of SAE, SRE, IEEE, and ASQ. Mr. Vannoy was inducted into the Univ. of Missouri-Rolla Academy of Electrical Engineering for his contributions to the reliability of automotive electrical and electronic systems. He began his career with General Motors Delco Electronics Div., establishing a product assurance group for computer systems. From there he served as supervisor of reliability and service activities at GM Emission Control System Center; supervisor of electrical and electronic groups in the Reliability Engrg. Dept. for Cadillac Motor Car Div; and as Mgr. of Product Assurance at AC Spark Plug Div. While at AC Spark Plug Div., he established an on-site master's degree program in reliability engineering. Mr. Vannoy has presented papers at ASQ, IIE, GM Product Engineering Technical Conf., Penn State Univ. Quality Assurance Seminar Series, Reliability and Maintainability Symposium, SRE, Univ. of Arizona Reliability Engrg. Management Inst., the Univ. of Arizona Reliability Testing Inst. and SAE. He has also given presentations abroad for several corporations. He serves on the SAE Reliability Comm. and has established reliability engineering courses with several universities.
Fees: $785 SAE Members*: $628 - $707
* The appropriate SAE Member discount will be applied through the Registration process.  Discounts vary according to level of membership: Elite Member 20%; Premium Member 15%; Classic Member 10%
CEU .7