Introduction to Failure Modes & Effects Analysis for Product Design & Manufacturing Process Design (Product & Process FMEA)
I.D. # 92002 Duration 2 Days
Designed to assist individuals responsible for design and development activities in the completion of a Design FMEA and Process FMEA, this course introduces participants to the analytical process in which potential failure modes, failure effects, and causes of failure are identified. Criticality and risk analysis concepts for dealing with the effects of failure will be covered. Analysis is used to identify corrective actions and controls necessary to eliminate failure modes or minimize the effect of failure.

Attendees will also receive the SAE Standard for FMEA, J1739, which is covered in the course materials. During the class, the instructor will review the updates to standard J1739 (revised Jan 2009).

Please note this seminar combines course material covered in ID# 90034, Introduction to Failure Mode & Effects Analysis for Product Design (Design FMEA) and ID# 90033, Introduction to Failure Mode & Effects Analysis for Manufacturing Processes, Assembly Processes & Service (Process FMEA).
Learning Objectives
By attending this seminar, you will:
  • Know the benefits, requirements and objectives of an FMEA
  • Learn the steps and methodology used to analyze a Process FMEA
  • Expand your knowledge of a variety of tools utilized when performing an FMEA
  • Identify corrective actions or controls and their importance in minimizing or preventing failure occurrence
  • Know the objectives of the SAE Standard for FMEA, J1739
Who Should Attend
This seminar is designed for the product/design engineer, process design engineer, manufacturing engineer, development engineer, materials engineer, product assurance, design assurance, process assurance engineer, reliability engineer, test engineer, quality engineer, logistics/support engineer, and their management.
Prerequisites
Individuals attending the seminar should have a basic understanding of the product design process and product and manufacturing process design principles.
Seminar Content
  • Introduction & Overview
    • Definition
    • General discussion -- requirements for analysis; uses/objectives of analysis; benefit
    • 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) and 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 Supportive Tool
    • Introduction -- approach; FMEA relationship
    • FTA sequence
    • Analysis overview -- symbols; examples; workshop
    • Limitations
    • Benefits
  • Application
    • Combined FMEA/FTA
    • Detained FMEA examples
    • FMEA/FTA comparisons
  • Using the Results
    • Logistics Support Analysis (LSA)
    • Failure Prevention Analysis (FPA)
    • 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 is a consultant specializing in product design assurance, process design assurance, and reliability engineering. He began his career with General Motors Delco Electronics Division, establishing a product assurance group for computer systems, then he served as supervisor of reliability and service activities at GM Emission Control System Center, supervisor of electrical and electronic groups in the Reliability Engineering Department for Cadillac Motor Car Division, and Manager of Product Assurance at AC Spark Plug Division, where he also established an on-site master's degree program in reliability engineering.

Mr. Vannoy serves on the SAE Reliability Committee and has established reliability engineering courses with several universities. He earned a B.S. and M.S. in Electrical Engineering from the University of Missouri-Rolla and is a Registered Professional Engineer in the state of Indiana, a Certified Reliability Engineer, and a member of Eta Kappa Nu, SAE, SRE, IEEE, and ASQ.

Testimonial

"Great introduction to the FMEA process. A valuable tool for anyone involved in design or manufacturing."
Dustin D. Carver
Design Engineer
Multi-Contact USA

"Great program! Forced me to re-orient my methodology."
Dhiraj Tiwari
Senior Design Engineer
Stryker Medical

"Excellent course, exceeded my expectations and gave me the necessary tools to begin truly using DFMEAs as they were intended."
Kevin Schneider
Project Engineer
FTE automotive
Fees: $1285 SAE Members*: $1028 - $1157
* 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 1.3