FMEA for Robust Design: What, Why, When and How

Failure Modes and Effects Analysis (FMEA) is an integral part of product design activity applicable to any type of product or service. It is a qualitative and quantitative step-by-step approach for identifying and analyzing all actual and potential points of failure in a design, product or service. A successful team-based FMEA activity can use their collective experience with similar products to dramatically improve not only product performance but also reduce manufacturing issues at both a component and system and processing level.

This web seminar introduces the five basic types of FMEAs with emphasis on constructing a Design FMEA. Each column of the FMEA form is clearly explained using a typical FMEA example. This example can be a provided sample or a company sample provided candidate. The course covers various methods for clearly identifying product function at three levels, and associating distinct failure modes, effects and causes related to each function level. Special attention is given to Severity, Occurrence, and Detection and how to develop effective Risk Priority (RPN) strategies and Recommended Actions for significant RPNs.

All material is in conjunction with current industry standards.

What Will You Learn

By participating in this web seminar, you should be able to:
  • State the relationship between Product Development, Voice of the Customer (VOC) and the FMEA process
  • Recognize why and when to use the five types of FMEAs, specifically Systems and Design
  • Apply the FMEA process as a risk management technique
  • Organize an effective FMEA team and conduct FMEA work sessions
  • Adapt the steps to generate a FMEA process to your specific company needs
  • Develop and manipulate Risk Priority and Detection Strategies and customize Risk Ranking tables
  • Assign effective Recommended Actions

Is This Course For You

The course is designed for individuals who are involved in the development of new products and who seek to improve that process. Product development team members including, but not limited to, project and program managers, design and development, process, product, quality, and application engineers will find the course valuable. It is aimed primarily at these managers and engineers who will be facilitating or leading such FMEA activities. Directors, marketing and purchasing personnel will also benefit by understanding why the FMEA process is important to developing a safe and effective product.

Materials Provided

This data is not available at this time

Course Requirements

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Session 1
  • FMEA Introduction
    • Background and History
    • The FMEA Standards - MIL-STD_1629, SAE J1739, AIAG
    • Relationship of Design and Process FMEA in a design & manufacturing environment
Session 2
  • Five Types of FMEAs
Session 3
  • FMEA and Risk Management
    • Defining Risk Management
    • FMEA and Robust Design
    • FMEA as part of Design to Cost
    • FMEA as Product Liability Protection
Session 4
  • Managing the FMEA Process
    • Assembling the FMEA Team
    • Facilitator Role during the FMEA Process
    • Capturing the 6 Levels of Voice of the Customer (VOC)
    • The FMEA Database and FMEA Templating
    • Tips for standardizing concise expression of failure modes, effects and causes
Session 5
  • Column By Column Review of the FMEA - Part 1
    • Header
    • Item/Function - Primary, Secondary and Customer Satisfaction
    • Failure Mode
    • Effects and Severity
    • Causes and Occurrence
    • Controls and Detection
Session 6
  • Column By Column Review of the FMEA - Part 2
    • Calculating and Assessing RPN
    • Risk Tables and RPN assignment strategies
    • Recommended Actions
    • Responsibility and Target Dates
    • Verification