Failure Modes and Effects Analysis Workshop

The Failure Modes and Effects Analysis (FMEA) Workshop can be structured as a one-day introductory workshop or as a three-day hands-on workshop. The objective of the longer workshop is to create a Design Failure Modes and Effects Analysis (DFMEA) or a Process Failure Modes and Effects Analysis (PFMEA). Although completion may not be possible due to the complexity of a product, significant progress should be made to allow completion by group at later time. The workshop can further be oriented toward hardware or software products.

The workshop will cover the following:

1. Introduction to FMEA

  • Relationship to Design for Six Sigma (DFSS), Other Quality Frameworks, and Reliability
  • FMEA Definition & Purpose
    • Design FMEA
    • Process FMEA
  • Overview of the FMEA Worksheet
  • Benefits of FMEA’s
  • Inputs and Outputs to FMEA

2. Evaluating Potential Failures – The FMEA Process

  • Failure Mode Definition and Categories
  • Identifying Potential Failure Modes
  • Examples of Failure Modes – Design and Process
  • Determining Effects
  • Examples of Effects
  • Rating Severity
  • Severity Rating Definition and Tables
  • Determining Causes
  • Methods and Guidelines for Determining Causes
  • Rating Occurences
  • Occurrence Rating Definition and Tables
  • Identifying Controls
  • Types of Design and Process Controls
  • Rating Detection
  • Design and Process Detection Rating Tables
  • Assessing Risk
  • The Risk Profile Number (RPN)
  • Exercises to Perform FMEA Process Steps

3. Responding to Potential Failures – The FMEA Process

  • Developing an Action Plan
  • Assigning Responsibility
  • Follow-Up and Re-Evaluation
  • Managing Design Risk for a Project

4. Related Methodologies

  • Fault Tree Analysis
  • Mistake Proofing
  • Production Control Plans

5. Making it Happen

  • Managing FMEA’s
  • Important FMEA Keys to Success
  • Institutionalizing FMEA in your Organization

6. Optional FMEA Exercise – Analyze an Actual Company Product or Process