FMEA Training Course Outline

(Failure Modes and Effects Analysis)

C2C Solutions will customize all FMEA Training topics to fit our client’s objectives. The following represents a rough and typical outline for a 1 or 2-Day FMEA Workshop which is delivered in a 160 page “easy to follow” Course Reference Manual.

Introductions / Course Objectives

  • Opening Comments, Ground-rules, Introductions, Workshop Objectives, Logistics, etc.
  • FMEA Pre Test (Optional)

Introduction to FMEA

  • FMEA Purpose & Definition
  • Intro to the 7 Main Steps
  • The FMEA Worksheet
  • Inputs and Outputs to FMEA
  • Types of FMEA’s
  • Product, Manufacturing Process, Business Process, Equipment, Software, Service, etc.
  • Benefits and Purpose of Design FMEA’s
  • Benefits and Purpose of Process FMEA’s
  • History of FMEA
  • When to start FMEA’s
  • Pre-Requisites to FMEA
  • Understanding your Customers Needs
  • Developing & Evaluating Concepts
  • Defining the FMEA Project & Scope
  • Creating an Effective FMEA Team
  • Gather and review Reference Material

Developing Functions

  • Definition of a Function
  • The Function Worksheet
  • Methods for Function Analysis
  • Simple Brainstorming
  • The FAST Diagram (Function Analysis Systems Technique)
  • Product Function Modeling
  • Process Functional Modeling
  • Organizing the Functions
  • Product Example
  • Functional Flowcharts
  • Process Example
  • Class Participant Workshop

Developing Failure Modes

  • Failure Mode Definition
  • Failure Mode Thought Starters
  • Failure Mode Assumptions
  • Failure Mode Categories
  • DFMEA Example
  • PFMEA Example

Determining Effects & Severity Ratings

  • Effects Definition
  • Cause & Effect Relationship
  • Effects Examples
  • Severity Rating Definition
  • Severity Tables
  • Classification Column
  • Special Characteristics
  • Class Participant Workshop

Determining Cause & Occurrence Ratings

  • Cause Definition
  • Cause Guidelines
  • Assumptions when determining Causes
  • Techniques for determining Causes
  • Fishbone Diagrams
  • Classic Brainstorming
  • Fault Tree Analysis
  • 8D
  • Experience
  • Experiments
  • 5 Why’s
  • Cause Examples
  • Occurrence Rating Definition
  • DFMEA Occurrence Table
  • PFMEA Occurrence Table

Controls & Detection Rating

  • Controls Definition
  • Types of Design Controls
  • Types of Process Controls
  • Examples of Controls
  • When Controls are implemented
  • Detection Rating Defined
  • DFMEA Detection Rating Tables
  • PFMEA Detection Rating Tables
  • Class Participant Workshop

Assessing Risk

  • Risk Defined
  • The RPN
  • The Risk “Area Chart”
  • Risk Patterns

Driving an Action Plan

  • Recommended Action Definition
  • 3 Global Strategies
  • The Action Plan
  • Introduction to Production Control Plans
  • Action Plan Results

Custom Attendee Workshops (Optional)

  • Attendees start an actual project for their company
  • Determine a “topic”
  • Critique an existing Project
  • Plan the Project
  • Start the FMEA Project (Get instructions from instructor)

Integrating QFD with other Product Development Techniques

  • Learn how FMEA can integrate into Product Development Processes which include DFSS techniques (Control Plans, QFD, TRIZ, Innovation, Value Engineering, Taguchi Methods for Robust Design, Pugh Concept Selection, SPC, PM, and more).