This course is offered in China only and presented in Mandarin Chinese. The course materials are bilingual (English and Chinese).

This course is verified by Probitas as meeting the AS9104/3A requirements for Continuing Professional Development.

This courser will introduce the latest version (2019) of Failure Mode and Effects Analysis (FMEA) Handbook with a focus on DFMEA and PFMEA building. Each column of the FMEA document will also be explained in detail with FMEA examples. The course also includes an introduction to the logic for identifying technical risks and thinking tools for risk mitigation. In addition, various methods to identify the failure chain will be elaborated on, especially the changes in the severity, incidence and detection degree of risks and the application of AP priority. Suggestions for improving common mistakes in the implementation of FMEA for companies will also be provided. Throughout the course, participants are expected to do exercises and practical projects, and demonstrate and apply what they have learned.

• Understand the advantages, requirements and targets of FMEA Handbook 2019
• Use DFMEA for product design and PFMEA for process design
• Develop and interpret DFMEA and PFMEA forms
• Complete a typical DFMEA and PFMEA form
• Select the right project and team to complete a FMEA
• Use logics to analyze technical risks
• Use thinking tools to effectively reduce risks
• Understand common mistakes in implementing FMEA

• Core members of a product development team, such as project manager, product designer, testing, manufacturing, quality and reliability engineer and personnel who assist the product development team in manufacturing, assembly, or service
• Participants should have an engineering background with basic problem solving skills is optimal

Participants should have an engineering background with basic problem solving skills.

• Part 1: The establishment of prevention concept
  • Ice-breaking story
  • Phenomena in life
• Part 2: Fundamentals of FMEA
  • Goal of FMEA
  • To build a FMEA team
    • Roles, expertise, experience, communication
  • Timing to make a FMEA
  • Limits of FMEA
  • Mission and goal of FMEA
• Part 3: 7 steps of making a DFMEA
  • Step 1: planning and preparations
    • Project confirmation and boundaries
    • Determine a basic FMEA
    • Header of a FMEA form
  • Step 2: structure analysis
    • Flow chart
    • Structure tree
    • Collaboration between customer and supplier¿s engineering team
  • Step 3: function analysis
    • Functions
    • Requirements (characteristics)
    • Block diagram
    • P-diagram
    • Function relationship visualization
  • Step 4: failure analysis
    • Failure
    • Failure chain
    • Failure modes
    • Failure effects
    • Failure causes
    • Relationship between PFMEA and DFMEA
  • Step 5: risk analysis
    • Current preventive control
    • Current detection control
    • Scores of risk assessment, severity, frequency, and detection degree
    • Priority of actions
  • Step 6: optimization
    • Responsibility distribution
    • Status of measures
    • Evaluation of measure effectiveness
    • Continuous improvement
  • Step 7: documentation of results
    • Purpose
    • Writing a FMEA report

• Part 4: 7 steps of making a PFMEA
  • Step 1: planning and preparations
    • Project confirmation and boundaries
    • Determine a basic FMEA
    • Header of a FMEA form
  • Step 2: structure analysis
    • Flow chart
    • Structure tree
    • Collaboration between customer and supplier¿s engineering team
  • Step 3: function analysis
    • Functions
    • Requirements (characteristics)
    • Function relationship visualization
  • Step 4: failure analysis
    • Failure chain
    • Failure modes
    • Failure effects
    • Failure causes
  • Step 5: risk analysis
    • Current preventive control
    • Current detection control
    • Scores of risk assessment, severity, frequency, and detection degree
    • Priority of actions
  • Step 6: optimization
    • Responsibility distribution
    • Status of measures
    • Evaluation of measure effectiveness
    • Continuous improvement
  • Step 7: documentation of results
• Part 5: conclusion and discussion
  • How to implement FMEA effectively in a company?
  • Experiences of implementing FMEA in different companies
  • Misunderstanding and common mistakes in implementing FMEA
  • Maintenance of FMEA
  • Evaluation of FMEA effectiveness

Mr. Hou graduated from Zhejiang University and has MBA degree. He is a former senior QC project manager at CuLTURE China of Karlsruhe Institute of Technology, Germany, a certified Six Sigma Black Belt lecturer (in management and statistics) registered in China Association for Quality, and a national certified auditor for ISO9001&ISO14001 registered in China Certification and Accreditation Association.

With 16 years of experience in manufacturing management, he has in-depth knowledge of Six Sigma management, quality tools and quality systems, and can provide both specific and comprehensive solutions. He went on a study tour in Harvard University, engaged in advanced studies at Karlsruhe Institute of Technology and practiced in German factories. He is a field improver for integrated manufacturing sites who has a deep understanding of advanced western management theories, outstanding manufacturing experiences and management practices in China.

He has served in large foreign-funded enterprises as a certified Six Sigma Black Belt, management representative and quality manager who led and organized inhouse improvements and breakthroughs of business processes.