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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
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Definition and historical background.
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Examine applications and benefits.
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Review types of FMEA/FMECA and published
standards:
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Design FMEA (DFMEA), Process FMEA (PFMEA),
Machinery FMEA (MFMEA), System FMEA,
Service FMEA, etc.
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J1739, AIAG FMEA-3, MIL-STD-1629A, etc.
Basic Analysis
Process
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How to assemble the team and establish
Ground Rules for the analysis.
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How to gather and evaluate Data Sources.
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How to identify and evaluate Items.
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How to identify and evaluate Functions.
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How to identify and evaluate Failure
Modes.
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How to identify and evaluate Effects.
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How to identify and evaluate Causes.
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How to identify and evaluate Controls.
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How to identify and evaluate Risk.
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How to identify and evaluate Recommended
Actions.
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How to generate Charts and Reports
to visualize and publicize the analysis.
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Make Revisions and integrate FMEA/FMECA
into decision-making.
Risk Assessment
Methodologies
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Risk Priority Number (RPN) rating system
for risk assessment:
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Severity, Occurrence and Detection rating
scales.
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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
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Criticality Analysis methodology for risk
assessment:
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Quantitative and Qualitative Analyses.
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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
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Organizing information in databases and
projects.
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Working with databases with and without
Login Security.
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Working with Profiles and Libraries to customize
the interface and the analysis:
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Enable/disable and/or rename data fields.
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Determine rating scales and criteria.
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Set classifications, categories, priorities
and other menu options.
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Create phrase libraries to save time
and ensure consistency.
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Data entry shortcuts, including copy/paste,
import/export, phrase libraries, etc.
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Understanding the Hierarchical, Worksheet
and Filtered views.
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Defining properties of Analysis, Items,
Functions, Failures, Effects, Causes, Current
Controls and Recommended Actions.
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Using shortcuts and tips for data entry,
such as import/export, copy/paste, phrase
libraries, etc.
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Working with Links and Attachments.
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Working with RPNs and/or Criticality Analysis.
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Managing Recommended Actions.
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Generating and evaluating charts and reports.
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Database administration:
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Authorized database users.
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Database backups.
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Baselines and revision tracking.
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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
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Work through a detailed training guide with
step-by-step instructions to complete sample
analyses that demonstrate the capabilities
of the Xfmea software.
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Discuss implementation options for your
particular analysis procedures and reporting
requirements.
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