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Failure Mode & Effects Analysis For Manufacturing Processes, Assembly Processes & Service (Process FMEA)

Introduction

This course introduces participants to the analytical process in which potential failure modes, failure effects and causes of failure are identified. Criticality and risk analysis concepts are also covered for dealing with the effects of failure. Analysis is used to identify corrective actions that may be used to eliminate failure modes or minimize the effect of failure. Additionally, the analysis may be used to identify controls necessary to prevent failure occurrence.

Duration: 2 Days

Target Audience

Personnel directly involved with manufacturing, assembly and service processes.

Programme Objectives

At the end of the course, participants will be able to:

· List the benefits, requirements and objectives of an FMEA

· Explain the steps and methodology used to analyze a Process FMEA

· Compare a variety of tools utilized when performing an FMEA

· Identify corrective actions or controls and their importance in minimizing or preventing failure occurrence

Programme Outline

Introduction and Overview
- Definition
- General Discussion
  - Requirements for Analysis
  - Uses/Objectives of Analysis
  - Benefits
- Timing and Relationships
  - Level of Analysis (Detail)
  - Design FMEA versus Process FMEA

Performing a Process FMEA
- Pre-analysis Activities
  - Determine Required Functions
  - Develop Block Diagrams
  - Process Flow Diagrams
- Basic Analysis Methodology
  - Approach
  - Sequence
- Criticality/Risk Analysis (Prioritization)
- Typical Forms Used and Examples

Problems Encountered
- Application
- Timing
- Prioritization

Fault Tree Analysis as a Support Tool
- Introduction
  - Approach
  - FMEA Relationship
- FTA Sequence
- Analysis overview
  - Symbols
  - Examples
  - Workshop
- Limitations
- Benefits

Application
- Combined FMEA/FTA examples
- Detained FMEA examples
- FMEA/FTA Comparisons

Using the Results
- Logistics Support Analysis (LSA)
- Failure Prevention Analysis (MPA)
- Test Planning

Other Related Methods/Tools
- Checklists
- Lessons Learned
- SPC

Keys for Successful Implementation
- Activity as Process versus a Task
- Analysis by Group/Team versus Individual
  - Roles and Responsibilities
  - Use of Facilitators