Quality Management & Training

FAILURE MODE AND EFFECTS ANALYSIS (FMEA)

Failure Mode and Effects Analysis (FMEA) is an established technique used to identify and mitigate risks associated with manufacturing and assembly processes.

FMEA is applicable to a broad range of processes, including those which produce a raw material, an individual component, a sub-assembly, or a complete assembly.

FMEA is one of the key ‘core tools’.  ‘Core Tools’ are defined as the five supplemental techniques and methods which support the expectations of IATF 16949 (see links below):

Advanced Product Quality Planning (APQP)

Failure Mode and Effects Analysis (FMEA)

Measurement Systems Analysis (MSA)

Statistical Process Control (SPC)

Production Part Approval Process (PPAP)

The above courses can be delivered individually or as a consolidated programme of training.

 

BUSINESS BENEFITS

  • Emphasises defect prevention: Risks and concerns identified and addressed before serial production begins
  • Supports a risk-based approach and requirements of quality management systems, e.g. IATF 16949
  • Enables risks to be evaluated and actions prioritised
  • Reduces exposure to the Cost of Poor Quality (warranty claims, customer complaints & returns, compensation, etc.)
  • Assists an organisation to satisfy stakeholder needs and expectations

WHO SHOULD ATTEND?

The FMEA methodology requires a multidisciplinary approach, hence this course is intended for all personnel who are involved with manufacturing and assembly processes, including:

  • Project and manufacturing managers
  • Project and manufacturing engineers
  • Quality engineers
  • Team leaders and process personnel
  • Internal quality auditors
  • Other personnel who need to understand the principles and terminology in order to communicate effectively with customers and suppliers

COURSE OBJECTIVES

The delegates should understand:

  • The role of FMEA in new product introduction, process management and improvement
  • How costly process problems and product failures can be avoided
  • How to develop and interpret a FMEA
  • How other tools and techniques complement FMEA
  • The linkage with quality management requirements, e.g. IATF 16949, APQP / PPAP

On completion of the course, delegates will be a QM&T validated and certificated FMEA practitioner.

COURSE STRUCTURE

Introduction to Process FMEA (PFMEA)

Developing a PFMEA

  • Defining a process
  • Identifying Failure Modes, Effects and Severity
  • Special Characteristics
  • Causes and Occurrence
  • Process Controls and Detection
  • Interpretation of Ratings, Risk Prioritisation, Improvement Actions

Teams present their FMEA results.

COURSE OPTIONS

1.  Pre-course visit to develop and adapt the course and associated material to exactly suit the client’s needs. Can include branding the material with company style and logo.

2.  Pre and post course delegate assignment with QM&T support. The delegate’s assignment / project would be fully assisted and supported online and assessed by one of our qualified and experienced staff.  This work based assignment approach has regularly provided significant financial savings, reinforce lessens learnt and provided a practical demonstration of delegate competence.  This (on successful assignment completion) provides the delegates with a QM&T Practitioner certificate.  This approach is often useful where delegates may not (due to other pressures) be able to immediately apply the newly acquired knowledge.

3.  The book Quality Management Tools and Techniques, by: Geoff Vorley and Fred Tickle.

This book would be invaluable for the delegates to complete their pre and post course assignments and provides much greater information than could be delivered in a one day course.   The book also places the subject in context and is invaluable in supporting concepts such as Lean and other improvement approaches.

4. Delegate assignment presentation provides the delegate with the opportunity to demonstrate their achievements to a selected group such as; CEO and Directors, key Managers and Supervisors, Editor of the company magazine, etc.  This gives the delegate the opportunity to credit and recognise their performance and motivate others to emulate.

COURSE DATES AND COST

See Training Courses for price list and order form