Tuesday, 18 June 2013

Failure Mode and Effect Analysis ( FMEA )


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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