Introduction to Failure Mode and Effects Analysis for Product and Process

I.D. #

C1201

Duration

2 Days

Failure Mode and Effects Analysis (FMEA) is a systematic method for preventing failure through the discovery and mitigation of potential failure modes and their cause mechanisms. Actions are developed in a team environment and address each high: severity, occurrence or detection ranking indicated by the analysis. Completed FMEA actions result in improved product performance, reduced warranty and increased product quality. This course assists FMEA team members to apply severity, occurrence and detection rankings consistently and efficiently and explores, in detail, the linkage of the Design FMEA and the Process FMEA through special characteristics development and product and process design collaboration. The relationships between FMEA and other popular tools, including Fault Tree Analysis (FTA), Design Verification Plan and Report (DVP&R) and Control Plans will also be discussed. Participants can expect dynamic "hands-on" activities with in-class Design and Process FMEA creation, facilitation skill development and risk analysis best practices. Instruction and clarification will be provided for relevant portions of the SAE J1739 standard, Potential Failure Mode and Effects Analysis in Design (Design FMEA), Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA), a copy of which will be included with the course materials.

Learning Objectives

Upon completion of this seminar, attendees will be able to:

List the benefits, requirements, and objectives of an FMEA
Demonstrate the steps used in developing an FMEA
Follow the methodology to efficiently create an FMEA
Describe other tools used in, or related to the FMEA
Identify corrective actions resulting from proper FMEA development
Identify and classify the levels of risk requiring corrective action
Show the links between Design and Process FMEA
Demonstrate the FMEA¿s role in developing Special Characteristics and Design and Process Controls
Summarize the objectives of the SAE standard J1739

Who Should Attend

This seminar is designed for engineers involved with manufacturing, product design, reliability, testing, quality, development, logistics/support, product assurance/design assurance, materials, and their management or anyone responsible for the design and development of manufacturing, assembly or service processes in the completion of a Design or Process FMEA.

Prerequisites

Attendees of this seminar should possess a basic understanding of manufacturing assembly process, and design principles.

Seminar Content

DAY ONE

Pretest - Set baseline of knowledge and determine Voice of the Customer (participants) wants needs and desires
FMEA Process Overview

Introductions and course objectives
What is risk?
The history and purpose of FMEA
SAE J1739 introduction
FMEA - where it fits in the product development process
System/Subsystem/component Design FMEA
Manufacturing and Assembly Process FMEA
Machinery and Equipment FMEA (Logistics Support)

FMEA Development Methodology

Design FMEA development methodology - the three path model
Failure Mode Avoidance FMA /FPA Failure Prevention Analysis
Team structure and rules for efficiency - cross functional teams

The Links between Design and Process FMEA

Special characteristics (critical and significant)
Collaboration on special characteristics
Characteristics as inputs to PFMEA

Workshop 1: Review product and processes to be performed
Practical Application of the Design FMEA Technique

Robustness Tools: Interface Analysis/Boundary (BLOCK) Diagrams; Parameter Diagram (P Diagram)

Workshop 2: Construct Boundary/Block Diagrams and P Diagrams
Review of Days Activities and Q&A

DAY TWO

Methodology and Hands-on Experience
Path 1

Functions/Failure Modes/Effects of Failure/Severity
Severity ranking guidelines
Actions for high severity (9,10)

Workshop 3: Path 1 Exercise
Path 2

Causes/prevention controls/occurrence
Occurrence ranking guidelines
Inputs to FTA (Fault Tree Analysis)
Actions to eliminate and/or reduce cause probability

Workshop 4: Path 2 Exercise
Path 3

Test and verification methods
Detection ranking guidelines
Links to DVP&R
Actions to improve tests and verification techniques
RPN - Risk Priority Number

Workshop 5: Path 3 Exercise
Fault Tree Analysis Fundamentals

When to use FTA instead of or in combination with FMEA
Similarities and differences with FMEA
Symbols and structure
Cut set development

Workshop 6: FTA Exercise
Process FMEA Pre-Work

Process flow diagrams
Characteristics matrix (QFD III)

Workshop 7: Process FMEA Development (Three Path Model)
Keys to Success and Efficient FMEA Development

Technology blocks for failure mode/ cause mechanism history
FMEA legacy matrices (Lean FMEA)

Other Tools and Techniques Used or Related to FMEA
Statistical Process Control (SPC) for special characteristics
Design for Assembly and Manufacturing DFA/M
8D - Eight Disciplines of Problem Solving and FMEA Links
Role of FMEA software
Reliability and Maintainability (Logistics Support)
Q&A
Post Test and VOC Closure

Instructor(s):

Lee D. Dawson

Mr. Dawson has over 35 years of experience in Quality and Reliability engineering. President and CEO of Quality-One International since 1986, Mr. Dawson had previously held engineering and training positions at Ford Motor Company, and Wickes Manufacturing. As CEO of Quality-One, Mr. Dawson has consulted with hundreds of companies and trained thousands of quality and engineering professionals in Failure Mode and Effects and Analysis (FMEA) and Advanced Product Quality Planning (APQP). He periodically teaches these and other related quality and reliability courses for several colleges and universities in the US, Canada, and Australia and speaks at engineering related functions. Mr. Dawson has written and collaborated on several technical books and manuals including Murphy¿s Law Overruled (FMEA in Design, Process and Service), Ford Design Institute FMEA Handbook and AIAG Effective Error Proofing CQI-18. He has participated, written and presented numerous technical papers at ASQ, ASM and other professional organizations. Mr. Dawson has a B.S. in Metallurgical Engineering from Penn State University and is a Certified Quality Engineer (CQE), Certified Reliability Engineer (CRE) and is a Master Black Belt in the practice of Six Sigma.

Testimonial

"Lee is a master of the material and a superb communicator. I had no idea that 2 days of FMEA could be so much fun!"
Zac Chambers, PhD
Associate Professor
Rose-Hulman University

Fees:

$1325

SAE Members*:

$1055 - $1195

* 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