Duration
2 days
Course Objectives
- To prevent process and quality problems by executing the 7 step approach to perform Process Failure Mode and Effects Analysis (PFMEA)
- To identify high risk areas and take effective steps to mitigate the risks.
- As a practical and effective guide in applying FMEA in IATF16949 organization.
- Transition strategy from the previous AIAG FMEA (4th edition) to the AIAG VDA FMEA 1st edition.
In this step-by-step, hands-on Process FMEA workshop, you will learn:
- The objective and principles FMEA
- Purpose and considerations of FMEA.
- Why is there a need to do FMEA
- Management role in FMEA
- Foundation and family FMEA
- Step 1 Planning and Preparation
- Identify scope of FMEA with more resources focused on processes with high priority
- Set-up Project plan – InTent, Timing, Team, Task, Tools (5T)
- Documents needed for reference for PFMEA.
- Step 2 Structure Analysis
- Identify and breakdown the manufacturing system into Process Items, Process steps and Process Work Elements.
- Perform the Structure Analysis in a precise and concise method using information from process flow chart, information obtained from customer-supplier collaboration and 4M approach from Ishikawa.
- Step 3 Function Analysis
- Develop the information defined in Structure Analysis to complete the Function Analysis.
- Perform the Structure Analysis in a precise and concise method using information from process flow chart, information obtained from customer-supplier collaboration and 4M approach from Ishikawa.
- Step 4 Failure Analysis
- Identify failure causes, modes, and effects, and show their relationships to enable risk assessment.
- Identify the various possible failure modes e.g. failure to meet specifications, incorrect or inappropriate requirements, intermittent.
- Trace the effects of the failures to the various stakeholders such as internal customers, external customers, legislative bodies and end user.
- Identify the failure causes from the 4Ms, input from previous PFMEAs, negation of actions in Function Analysis.
- Understand the interrelation of DFMEA and PFMEA and link design weaknesses to potential failures in the PFMEA.
- Step 5 Risk Analysis
- Identify Current Prevention and Detection Controls incorporated in the process.
- Perform risk assessment by evaluating the Severity, Occurrence and Detection of fallout and assigning appropriate S, O and D numbers.
- Use the Action Priority method to prioritize actions to be taken to mitigate the risk.
- Step 6 Optimization
- The purpose of the Process Optimization Step is to determine suitable actions to mitigate risk for high Action Priority items.
- Select suitable actions that are able to mitigate high risk items by improving the process or improving the detection ability.
- Apply Poka Yoke devices / concepts to prevent and detect defects.
- Implementation and documentation of actions taken.
- Assess the effectiveness of the actions taken.
- Step 7 Results Documentation
- Summarize and communicate the results of the FMEA.
- Confirmation of the effectiveness of implemented actions and assessment of risk after actions taken.
- Develop plan and commitment of timing for ongoing FMEA improvement actions.
- Develop a suitable Transition Plan from AIAG FMEA 4th Edition to AIAG VDA FMEA 1st Edition
- Key differences and major changes in the new FMEA.
- Status of matured products currently evaluated using the old AIAG FMEA 4th Edtion.
- Collaboration with customer on the transition plan.
Who Should Attend
All quality, engineering, manufacturing, design, management and customer support personnel involved in Failure Mode and Effects Analysis.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.