FMEA Training Course Outline

Day One

Introduction and Voice of the Customer (VOC)
FMEA Process Overview
- What is Risk?
- History and Purpose of FMEA
- Standards and Guidelines to be followed
- FMEA – Where it fits in the Product Development Process
- System / Subsystem / Component Design FMEA
- Manufacturing and Assembly Process FMEA
- Machinery and Equipment FMEA
- Typical Applications – Aerospace, Medical, Automotive, Machinery, etc.
FMEA Development Methodology
- Failure Mode Avoidance (FMA) & Failure Prevention Analysis (FPA)
- Team Structure and rules for efficiency – Cross Functional Team (CFT)
Links Between Design and Process FMEA
- Special Characteristics (Critical and Significant)
- Collaboration on Special Characteristics
- Characteristics as Inputs to PFMEA
Workshop 1: Review Product and Processes to be performed
Practical Application of the Design FMEA Technique
- Robustness Tools: Interface Analysis / Boundary (Block) Diagrams; Parameter Diagram (P Diagram)
Workshop 2: Construct Boundary / Block Diagrams and Parameter Diagrams
Day One Review and Q&A

FMEA Development Methodology – Three Path Model
- Path 1
  - Functions / Failure Modes / Effects of Failure / Severity
  - Severity Ranking Guidelines
  - Actions for High Severity (9 and 10)
- Path 2
  - Causes / Prevention Controls / Occurrence
  - Occurrence Ranking Guidelines
  - Inputs to Fault Tree Analysis (FTA)
  - Actions to eliminate and / or reduce cause probability
- Path 3
  - Test and Verification Methods
  - Detection Ranking Guidelines
  - Links to DVP&R
  - Actions to improve tests and verification techniques
  - Risk Priority Number (RPN)
FTA Fundamentals
- When to use FTA instead of, or in combination with, FMEA
- Similarities and Differences with FMEA
- Symbols and Structure
- Cut-set Development
Workshop 3: FTA
Process FMEA Pre-Work
- Process Flow Diagrams
- Characteristics Matrix (QFD III)
Workshop 4: Process FMEA Development
Keys to Success and Efficient FMEA Development
- Technology Blocks for Failure Mode / Cause Mechanism History
- FMEA Legacy Matrices (Lean FMEA)
Other Tools and Techniques Used or Related to FMEA
- Statistical Process Control (SPC) for Special Characteristics
- Design for Assembly and Manufacturing (DFA / M)
- Eight Disciplines of Problem Solving (8D) and FMEA Links
- Role of FMEA Software
- Reliability and Maintainability
Day Two Review and Q&A
Post Test and VOC Closure