FMEA TOWARDS MANUFACTURING EXCELLENE – FAILURE MODE EFFECT & ANALYSIS

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Private Class from

2700/day

(2 Days)

COURSE OBJECTIVES

· Prevent failure mode from occurring

· Defining the Severity (SEV), Occurrence(OCC) and Detection (DET) indexes to prioritize recommended action plans, RPN

· Develop action plans through root causes analysis

· Understand both the Process and Design FMEA

· Learn to predict and identify failure mode or before failure happen

· Understand where problem or error could begin

· Develop action plans as to prevent failure mode from happening

· Able to use a standard form as a guide to complete FMEA

· Prioritize the most crucial areas to work on

· Organization could greatly improve quality, productivity and cost in managing quality and processes at source

INTRODUCTION

One of the reasons Quality is always an issue is because it already “happened” before we knew it, which means it already occurred – also known as “After the Fact” phenomena. In most cases they were in a way allowed to happen, or the process that caused error was overlooked in the first place. Ideally, a method to achieve Zero Defect is to prevent it from happening in the first place, even before manufacturing operations begin.

Fundamentally, the main purpose of Failure Mode Effect & Analysis, FMEA looks into “Before the Fact” scenarios as oppose to allow quality issues to surface and only then react upon it. FMEA works toward addressing the issues during the product design or process development stage. Hence, problems and errors are identified and prevented before it happened. In this course, Process FMEA or PFMEA is being introduced as part of the mainstream learning as most of the local manufacturing outfits are of process assembly nature. The Design FMEA or DFMEA is also mentioned here as an overview where both these FMEAs have similar approaches.

Failure Mode Effect & Analysis is structured by a standard form that systematically guides users to follow and apply. The form leads users to fill them in as to complete the FMEA process. There are 3 types of table used in order to provide the best fit ranking of SEV, OCC and DET available for each failure mode. Eventually appropriate and relevant action plans are generated and implemented. A complete FMEA shall consist of 2 sets of Recommended Prioritize Numbers, RPN where the latter index is expected to be lesser to indicate improvement.

TARGET AUDIENCE

· Level – Managers, Executives & Engineers

· Department – Engineering, Production & QA

· Industry – Manufacturing

METHODOLOGY

· Approx 20:80 rule - 20% sharing, & 80% learning activities

· Accelerated learning - Highly interactive with experience facilitator

· Implied & Work related learning activities with highly engaging interactions

Module 1: Introduction

· Course Objectives

· Develop & Analyzing Possible/Potential Failures

· Learning Activities

Module 2: FMEA Overview

· Background

· Definition

· Benefits of FMEA

· Types of FMEA

· Product Reliability

· Key Elements of FMEA

· Learning Activities

Module 3: Purpose of FMEA

· Analyzing failure / quality issue

· Description of FMEA

· Learning Activities

Module 4: Understanding FMEA

· Process FMEA form

· Illustration of Process FMEA

· Learning Activities

Module 5: “Process FMEA” steps & exercise