Design and Process Failure Modes and Effects Analysis (FMEA)
I.D. # C1510 Duration 2 Days
This seminar covers the five types of FMEAs with emphasis on constructing Design and Process FMEAs. Each column of the FMEA document will be clearly explained using an actual FMEA example. The course covers various methods for identifying failure modes, effects and causes with special attention given to severity, occurrence, and detection tables and how to develop effective recommended actions strategies. Throughout the class, participants will be involved in exercises/actual projects that demonstrate and incorporate direct application of learned principles.
Learning Objectives
By attending this seminar, you will be able to:

  • Describe the benefits, requirements and objectives of an FMEA
  • Describe the five types of FMEAs and how to use them
  • Develop and interpret a Design and Process FMEA form
  • Identify and utilize various tools when performing an FMEA
  • Describe the standard requirements/recommendations for an FMEA
  • Select suitable projects and teams for completing an FMEA
  • Complete a typical Design and Process FMEA form

Who Should Attend
This seminar is designed for core members of a Product Development Team such as project managers, product design, test, manufacturing, quality, reliability engineers and those responsible for assisting the PDT in design and development of product, manufacturing, assembly or services processes.
Participants should have basic problem solving skills typical of a graduate engineer.
Seminar Content

  • Understanding and Application of FMEA

    • FMEA as Part of the Product Development Life Cycle
    • The Various Industry FMEA standards
    • Why and When to use Concept, System and Design FMEAs
    • The FMEA as a Risk Management Technique
    • FMEA, Robust Design, and Design Reviews
    • FMEA vs FMECA
    • Using FMEA to Address Product and Process Liability Issues

  • Managing the FMEA Process

    • The Steps to Generating a Quality FMEA
    • The Essentials of an Effective FMEA Database and Template FMEAs
    • Methods for Selecting Suitable Projects for Templating Design and Process FMEAs
    • FMEA Team Development
    • Champion and Facilitator Roles during FMEA Development

  • Introducing the FMEA Exercise - Designing a Great Flashlight


  • Constructing a Useful FMEA

    • The Five Types of FMEAs and the Uses
    • Design FMEA

      • Constructing the boundary and block diagrams
      • Column by column review of the Design FMEA form
      • Development of a company-specific table structure for severity, occurrence and detection
      • Techniques for RPN prioritization and developing recommended action
      • Developing effective design control techniques
      • Exercise 2 - Completing the Flashlight Design FMEA

    • Process FMEA

      • Gathering the necessary process documents
      • Column by column review of the Process FMEA form
      • Development of a company-specific table structure for severity, occurrence and detection
      • Techniques for RPN prioritization and developing recommended action
      • Exercise 3 - Completing the Flashlight Process FMEA
      • Application of the Machinery FMEA
      • Effective use of the occurrence and detection tables
      • Validating process and machinery control techniques

Instructor(s): Angelo Mago
Angelo Mago

Angelo Mago is senior consultant and owner of ATM Consulting, Inc., which provides customized training and consulting services to a varied design and manufacturing supplier community in the areas of quality assurance, quality control, design engineering, document management, and customer service and improvement methods. He has acquired experience since 1993, in product design, quality assurance, project management working in DOD in the M1 Abrams and Bradley Program Management offices and as the Senior Supplier Quality Engineer for GM Truck Group responsible for NAO and off-shore supplier ISO qualification, Product Development, and PPAP qualification and approval. Through ATM Consulting, Mr. Mago has played a lead role in establishing a PM and APQP environment for both large and small companies. He is a recipient of the SAE Forest R. McFarland Award for distinction in professional development/education. He has a B.S. in Mechanical Engineering from Florida Institute of Technology.
¿Very interesting class, covering from A to Z the FMEA process, or from F to A I should say.¿

Michael Halim

Product Engineer

Hutchinson FMS


Fees: $1595 SAE Members: $1436


CEU 1.3