Failure Mode and Effect Analysis for Product/Process Development
I.D. # C0562 Duration 3 Days

The automotive industry is undergoing fierce competition globally. To increase competitiveness, automotive OEMs and suppliers are striving for improving quality and customer satisfaction, eliminating warranty, and reducing product development cycle time. This seminar introduces the participants to FMEA, an effective and powerful quality improvement tool.

The seminar prepares the participants to effectively identify failure modes, determine effects, concisely define root causes of the failure modes, and successfully develop and implement the corrective actions. The seminar will teach the participants how to use FMEA to capture their thoughts as they develop a product or process. This systematic approach formalizes and documents the mental discipline that an engineer normally goes through in any design or manufacturing planning process.

The seminar will also introduce some latest ideas of reliability methods aimed at failure mode avoidance through robust engineering and mistake elimination. By attending this seminar, the participants will recognize that failure modes are created  at different stages of product design process, and it is cost-effective and less time-consuming to discover failure modes and develop counter measures at early stages of the product design process.

This course uses the SAE FMEA Standard J1739.

Learning Objectives
By attending this seminar, you will be able to:
  • Describe what FMEA is, who should develop FMEA, and when FMEA should be done
  • List the benefits and objectives of FMEA
  • Develop P-diagrams and identify five noise factors   
  • Recognize and evaluate the potential failure of a product, its effects, and root causes
  • Identify and develop counter measures that could eliminate or reduce the chance of the potential failure occurring
  • Document the process 
  • Describe the relationship between DFMEA, DVP&R, PFMEA, and Control Plan
  • Analyze and review FMEA

Who Should Attend
Product Design Engineers, Product Development Engineers, Product Assurance Engineers, Quality Engineers, Reliability Engineers, and their management. The participants should have a basic understanding of engineering and design principles.
Participants should have a bachelor's degree in engineering.
Seminar Content
Day One
  • Introduction
  • FMEA Definition
  • Benefits of FMEA
  • Where FMEA fits into the product development process
  • Preparation for developing a FMEA
  • Quality History
  • Block Diagrams  

Day Two

  • Development of a Design FMEA

    • FMEA header
    • Item/Function/Requirement
    • Potential Failure Mode
    • Potential Effect(s) of Failure
    • Severity (S) and Classification
    • Potential Cause(s) of Failure
    • Occurrence (O)
    • Current Design Controls
    • Detection (D) and Prevention
    • Risk Priority Number (RPN)
    • Recommended Action(s)
    • Responsibility and Target Completion Date
    • Action Results (Actions Taken and Effective Date, Revised Ratings)

Day Three

  • Development of a Process FMEA

    • FMEA header
    • Process Function/Requirements
    • Potential Failure Mode
    • Potential Effect(s) of Failure
    • Severity (S) and Classification
    • Potential Cause(s)/Mechanism(s) of Failure
    • Occurrence (O)
    • Current Process Controls
    • Detection (D) and Prevention
    • Risk Priority Number (RPN)
    • Recommended Action(s)
    • Responsibility and Target Completion Date 
    • Action Results (Actions Taken and Effective Date, Revised Ratings) 

  • Summary

Instructor(s): Jay Zhou

Dr. Jianhua Zhou is Consultant at JHZ Strategic QA. Prior to this, he worked for Ford Motor Company where he held various positions including Vice President of Ford Asia Pacific Quality and New Model Programs, Corporate Executive Technical Leader and Member of Technology Advisory Board. Dr. Zhou has been actively involved in professional societies. He is Fellow of American Society for Quality and Chief Technical Expert of ASQ Shanghai. He also serves as an Associate Editor of SAE International Journal of Materials and Manufacturing.

As Corporate Executive Technical Leader, Dr. Zhou was responsible for developing and deploying Corporate Quality Strategy, Quality Systems and Quality Business Plan throughout Ford World. He trained more than fifteen thousand engineers in Asia Pacific, North America, South America, Europe and South Africa. His training subjects include quality, reliability, robust engineering, problem solving and failure mode avoidance.

As Vice President of Ford Asia Pacific and then Ford China Quality and New Model Programs, Dr. Zhou was responsible for vehicle and powertrain new model launches and prototype builds throughout Asia Pacific region

Dr. Zhou has published more than thirty technical papers including the one on Japan Journal of Quality Forum. He has been a key note speaker and panelist at various international conferences and symposiums. He was a three-time award winner of Taguchi Robust Design. In 2009 ASQ recognized Dr. Zhou the Quality Professional of the Year. In 2015 ASQ bestowed him ASQ Fellow for his contribution to advancing quality. He holds a US patent on vehicle durability.

Dr. Zhou earned his M.S. and Ph.D. degrees from University of Michigan, and his B.S. degree from Nanjing University of Technology.

Fees: $1782 SAE Members: $1604