Course Outline

Day 1 Morning 8:30 a.m. to 11:45 a.m.
The morning session of Day 1 provides an introduction to and overview of the fundamentals of Failure Mode and Effects Analysis (FMEA) and Failure Mode, Effects and Criticality Analysis (FMECA), including a thorough instruction in the proper identification of failure modes, effects, causes, controls, risk assessment and corrective actions. Topics include:

Introduction and Overview

• Definition and historical background.
• Examine applications and benefits.
• Review types of FMEA/FMECA and published standards:
  • Design FMEA (DFMEA), Process FMEA (PFMEA), Machinery FMEA (MFMEA), System FMEA, Service FMEA, etc.
  • J1739, AIAG FMEA-3, MIL-STD-1629A, etc.

Basic Analysis Process

• How to assemble the team and establish Ground Rules for the analysis.
• How to gather and evaluate Data Sources.
• How to identify and evaluate Items.
• How to identify and evaluate Functions.
• How to identify and evaluate Failure Modes.
• How to identify and evaluate Effects.
• How to identify and evaluate Causes.
• How to identify and evaluate Controls.
• How to identify and evaluate Risk.
• How to identify and evaluate Recommended Actions.
• How to generate Charts and Reports to visualize and publicize the analysis.
• Make Revisions and integrate FMEA/FMECA into decision-making.

Risk Assessment Methodologies

• Risk Priority Number (RPN) rating system for risk assessment:
  • Severity, Occurrence and Detection rating scales.
  • RPN calculations, charts and graphs.
• Other Risk Assessment Methodologies
  • Assessment using Occurrence/Severity Matrix
  • Rating Scale Comparison
  • Severity X Occurrence Metric
  • Risk Ranking Tables
  • Combination Triggers
• Criticality Analysis methodology for risk assessment:
  • Quantitative and Qualitative Analyses.
  • Criticality Reports and Matrices.

Integration with Other Quality Analyses (APQP)

• Design FMEA input to Process FMEA.
• Design FMEA input to Design Verification Plan and Report (DVP&R).
• Process FMEA input to Process Control Plan.
• Process Flow Diagrams.
• Using FMEA to guide development of Maintenance Plans.

Day 1 Afternoon 1:00 p.m. to 4:30 p.m.
The afternoon session of Day 1 emphasizes the practical aspects of FMEA/FMECA, including the key elements of successful FMEAs and pitfalls to avoid. Topics include:

Key Factors for Effective FMEA Projects

• How to define the scope, assumptions and limitations that bring about a focused and successful FMEA project.
• Common errors and failures in FMEA practice.
• What should be the size and make up of he FMEA core team, and what backup support is needed?
• What are characteristics of successful FMEA facilitation?
• How to maximize the value of team meeting time
• What pre-work is needed before first meeting.
• How to determine the columns in FMEA worksheet for maximum effectiveness.
• What are FMEA Quality Objectives and how are they used to ensure highest quality result?
• What management reports, reviews and support are necessary to effective FMEAs?
• What are the seven pitfalls to effective FMEAs and how can they be avoided?
• What other tips make for successful FMEA outcomes?

Design FMEA Exercise

• Attendees will form an FMEA team and carry out the fundamental steps of a Design FMEA, learning to avoid the pitfalls.

Process FMEA Exercise

• Attendees will form an FMEA team and carry out the fundamental steps of a Process FMEA, learning to avoid the pitfalls.

Day 2 Morning 8:30 a.m. to 11:45 a.m.
The morning session of Day 2 introduces Xfmea and covers many of the features of this versatile software, from setting up the database to generating FMEAs and reports. Topics include:

FMEA Data Management

• Organizing information in databases and projects.
  • Working with databases with and without Login Security.
• Working with Profiles and Libraries to customize the interface and the analysis:
  • Enable/disable and/or rename data fields.
  • Determine rating scales and criteria.
  • Set classifications, categories, priorities and other menu options.
  • Create phrase libraries to save time and ensure consistency.
• Data entry shortcuts, including copy/paste, import/export, phrase libraries, etc.
• Understanding the Hierarchical, Worksheet and Filtered views.
• Defining properties of Analysis, Items, Functions, Failures, Effects, Causes, Current Controls and Recommended Actions.
  • Using shortcuts and tips for data entry, such as import/export, copy/paste, phrase libraries, etc.
• Working with Links and Attachments.
• Working with RPNs and/or Criticality Analysis.
• Managing Recommended Actions.
• Generating and evaluating charts and reports.
• Database administration:
  • Authorized database users.
  • Database backups.
  • Baselines and revision tracking.
• Configuring the workspace (User Setup).

Day 2 Afternoon 1:00 p.m. to 4:30 p.m.
The afternoon session of Day 2 is a hands-on workshop, tailored to individual applications.

Hands-on Workshop

• Work through a detailed training guide with step-by-step instructions to complete sample analyses that demonstrate the capabilities of the Xfmea software.
• Discuss implementation options for your particular analysis procedures and reporting requirements.