Duration
2 days
Course Objectives
- To prevent process and quality problems by identifying potential failures in a design/production process.
- To take effective actions to mitigate high risk failures.
- To highlight FMEA guidelines in the AIAG 4th edition.
- As a practical and effective guide in applying FMEA in IEC16949 organization.
In this step-by-step, hands-on FMEA workshop, you will learn:
- Brief history and principles of FMEA
- How and why it works
- Why is it superior to other problem solving tools
- The need for management to participate and support in FMEA
- Avoid common pitfalls in FMEA implementation.
- Effective application of Process FMEA
- Identify potential product and process related failures.
- Tools to establish root cause of process failures.
- Assess the severity of the failures with respect to customer expectations, product performance and safety issues.
- Evaluate the likelihood of occurrence of a failure.
- Evaluate effectiveness of existing process controls put in place to prevent or detect failures.
- Assigning severity(S), occurrence (O) and detection (D) numbers
- Calculate Risk Priority Number (RPN) and understanding its implications.
- Take actions to reduce the severity of failure, likelihood of occurrence and to improve prevention and detection controls.
- Examples of effective actions taken and less effective actions taken.
- Criteria for your actions taken to be effective in controlling, reducing or eliminating your problem.
- Evaluate if actions taken are adequate.
- The link between process FMEA, design FMEA and other documents.
- Understand the additional requirements in AIAG 4th edition and differences with the earlier editions.
- Hands-on application of Process FMEA.
- Mistake proofing (or Poka Yoke) as a preventive action or corrective action tool to prevent failures.
- Understand the concept of mistake proofing a design or process.
- Tools to prevent or detect process failures.
- Select most appropriate mistake proofing tools to use : mistake proofing by shutdown, control, or warning, or a combination of two or more tools.
- Install practical systems that prevent and eliminate failures.
- Practical examples of mistake proofing in the electronics, automobile, chemical, medical and food industry.
- Case studies in mistake proofing applications.
- Design FMEA
- Purpose of Design FMEA, differences and similarities with Process FMEA
- Perform Design FMEA to assess and identify risks and weakness in a product design.
- Assess the severity of the failures with respect to customer expectations, product performance and safety issues.
- Evaluate the likelihood of occurrence of a failure.
- Methods to improve product design, addition of mistake proofing features and add more vigorous testing methods to detect design flaws.
- Use FMEA as an effective input to a Control Plan. Ensure that your FMEA, Control Plan and other documentation are updated systematically for an improved quality performance and updated information.
Who Should Attend
All quality, engineering, manufacturing, design and customer support personnel involved in Failure Mode and Effects Analysis.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.