FMEA Practitioner

Summary

Our 2-day FMEA Practitioner Course will equip delegates with the skills necessary to lead and facilitate the generation of FMEAs, while confidently guiding and managing contributors to the FMEA activity.

It provides a natural progression for anyone who has completed our 1-day FMEA Introduction course or an equivalent introductory level of training. Participants will learn how to create, maintain, and integrate robust DFMEAs, and PFMEAs; and how they support strong product and process performance, and Control Plans.

It is also well-suited to in-company delivery and can be customised to reflect your products, services, and operational context. Delivery will include presentations, facilitated discussion, interactive exercises and group activity workshops.

How will I benefit?

At the end of this course delegates will understand:

  • the risks of non directed FMEA activity
  • effective facilitation techniques for leading FMEA workshops
  • how to structure function and failure analyses
  • best practices for risk scoring and action prioritization
  • prevention vs detection controls and how to improve risk ratings
  • how to document, maintain, and update professional FMEAs
  • how to connect DFMEAs, PFMEAs and Control Plans

Who should attend?

This course is particularly suited to Engineers, Quality Specialists and Technical Leads who are responsible for:

  • the implementation of an FMEA framework
  • improving the FMEA application / standards in an organisation or their supply chain
  • leading FMEA teams
  • chairing FMEA review meetings

Course Outline / Key Topics

Gaining buy-in and traction for managed FMEA activity

  • Understanding the risks of non directed FMEA activity
  • Demonstrating the cost benefits of FMEA to the business
  • Selling the benefits to the wider team and the positive impact on individual roles

How FMEA supports product development, process design and manufacturing

  • Managing customer requirements and working with your suppliers
  • Design reviews

Effective facilitation techniques for leading FMEA activity

Information Gathering: Data Sources

Stepping through the FMEA Process

  • A deeper dive into the systematic approach of FMEA
  • The importance of starting with Boundary Diagrams and Interface Matrices
  • Defining the SI Units
  • Creating and reflecting the functions
  • Use of Functions Checklists
  • Transferring Functions onto the FMEA Template

A detailed review of Failure Modes and the effects of failure

  • Failure modes – understanding the differences
  • Where the failure modes are created and observed
  • Categories of severity

Identifying Root Causes and Controls

  • Managing Root Cause Analysis sessions
  • Fishbone Diagrams and 5-Whys

Best practices for scoring and action prioritization

  • Severity, Occurrence and Detectability
  • Use of score cards
  • Why businesses are moving away from RPN to Action Priority
  • How to avoid being misled by the numbers

Prevention vs detection controls and how to improve risk ratings

  • Methods of prevention
  • Deeper dive into Detection Controls

How to document, maintain, and update professional FMEAs

  • Setting responsibilities
  • Version Control
  • Making FMEAs accessible
  • Living breathing documents
  • Alignment to gateways

Connecting DFMEAs, PFMEAs and Control Plans

  • Critical and Significant Characteristics
  • Transferring outputs from your DFMEA to the PFMEA and Control Plan
  • Use of design guides, rules and standards for completing recommended actions