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
- 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