Objectives
At the end of this training programme, participants will be able to, among others:
1. Understand the purpose and benefits of FMEA
2. Understand the FMEA Methodology
3. Create detail Process Mapping
4. Construct Cause & Effect Matrix
5. Create an FMEA by applying the methodology and process steps using a case study
6. Understand the application of FMEA supporting RCA, Prevention and Detection tools
The Model:
1. Process Selection Process Mapping
2. Cause & Effect Matrix
3. Process FMEA
4. Control Plans
Course Content
1. FMEA Overview
- History of FMEA
- What is FMEA?
- FMEA Model
- FMEA link to problem prevention
- Benefits of FMEA
- Types of FMEA – design, process, equipment
- FMEA in product life cycle
- Roles and responsibilities
- Steps in filling up FMEA template
- FMEA Process Steps and Flow
2. Prepare FMEA
- Define Scope
- Define Objectives and Success Criteria
- Define Team
- Review FMEA Process
- Gather Relevant Information
- Prepare Preliminary FMEA
- Example – marking process
3. Develop FMEA
- Define Unit Process flow Steps
- List Potential Failure Modes
- List Potential Failure Effects
4. Assign Severity Rating
- Severity overview/guideline
- Relationship of failure/effect/cause
- Occurrence guideline
- Detection overview/guideline
- RPN guideline
5. Act on FMEA Results
- Prioritize Failure Mode
- Determine recommended action
- Assign owner(s) to action
- Data collection
- Revise FMEA
6. FMEA deployment & Follow-up
- RPN guidelines
- FMEA and criticality
- When to revise FMEA?
Selecting and Developing an In-House Process FMEA:
1. Form a team, with three to four groups
2. Select appropriate critical process
3. Developing a Process Mapping
4. Developing a Cause and Effect Matrix
5. Developing a Preliminary FMEA
6. Focusing on High RPN Numbers
7. Preparing Final FMEA and Reporting
Understanding and application of supporting RCA, Prevention and Detection tools of FMEA:
1. Ishikawa "Fishbone" Diagram
2. Sentencing Technique
3. The Global 8D Problem Solving Approach
4. Flowcharts & Process Mapping
5. Basic Anova (Basic DOE)
6. Statistical Process Control
7. Poka-Yoke (Mistake-Proofing)
8. Control Plan
9. FMEA Software
10. 5 Whys Techniques
11. Normality Test
12. Histograms
13. Pareto Charts
14. Basic Statistics
15. Cause & Effect Matrix
Target Audience
Managers/QA Engineers/Technicians/supervisors/QA staffs who wish to apply FMEA to proactively manage the operation issues or abnormalities to stay competitive in the market by using this systematic, scientific approach.
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