Failure Modes and Effects Analysis (FMEA) & Root Cause Analysis

Overview

Failure Modes and Effects Analysis: FMEA is a logical process based methodology for identifying all possible failures in process or product. It can be applied to services and business processes as well as product design and manufacturing processes.

A properly executed FMEA should result in corrective actions to address failures that have been observed as well as preventive actions to enable avoidance of potential failure modes that have been discovered.

Gain a working knowledge of the FMEA process for products, processes, or systems in this one-day class. A failure modes and effects analysis (FMEA) helps analyze a proposed or existing process or product to uncover potential failures within the product, process, or system before they occur. The introductions and hands-on classes will teach you how to construct and analyze both product and process FMEAs.

Root Cause Analysis: Don’t just put a bandage on a problem – fix it permanently. A root cause is the fundamental, underlying reason for a problem. Root Cause Analysis is an approach for identifying the underlying causes of why an incident occurred so that the most effective solutions can be identified and implemented. This class enables you to define your problem, identify the cause of the problem, solve it, and prevent it from occurring again.

Target Audience

Anyone involved in identifying and reducing risk
Design engineers
Process owners or process engineers
Those in quality assurance
Research and Development personnel
Individuals responsible for new product introduction
Quality, safety, risk, and reliability managers
Operations supervisors
And anyone who wants to improve their ability to solve recurring problems should attend this training

Prerequisites

Engineering or Manufacturing experience recommended

Duration

2 day

Venues

Classroom, Onsite

Price

$1200

Learning Objectives

Day 1 FMEA:

Define the types of FMEAs
Identify the benefits of FMEAs
Understand the components of a FMEA
Describe process requirements
Explain the impact of team selection on the FMEA
Manage the FMEA over the life of the process

Day 2 Root Cause Analysis:

How to clearly define the problem
How to characterize the process where the problem is
When to use anecdotal evidence and when to use hard data
How to develop a sampling strategy and collect data
Several analytical tools and when each is most appropriate
Strategies to improve processes and prevent recurrence of the root cause

Course Content

Day 1 FMEA:

Introduction to Failure Mode Effects Analysis (FMEA) – One (1) Hour

Format: WebEx – generally presented as a Lunch & Learn
Tools: Interactive A/V presentation and dialogue
Deliverables: An introduction to FMEA and how to get the most value from them.
Outcomes: Awareness and understanding of how to apply FMEA and potential to plan for an effective training and deployment plan for your organization.

How to Perform a Process FMEA – Two (2) Hours (FMEA Intro)

Format: WebEx
Tools: Interactive A/V presentation and dialogue
Deliverables: Basic training in application and deployment of process FMEA.
Outcomes: Participants will be capable of performing a process FMEA. They will also understand the requirements and competencies required to perform a process FMEA to facilitate planning for who should participate in your organization.

Complete Process and Design FMEA Training with Templates – One (1) Day (FMEA Base)

Format: Client Site with 10-20 participants
Tools: Interactive A/V presentation, FMEA templates, interactive exercises
Deliverables: Complete training and skill development on the creation of process & design FMEAs.
Outcomes: Participants will be capable of performing a process & design FMEA. They will also understand the requirements and competencies necessary to perform a process FMEA and help facilitate planning for who should participate in your organization.

FMEA Hands on Project Application – One (1) Day (FMEA P/A)

Format: Optional 2^nd day offered in conjunction with (3a) working with the same 10-20 participants
Tools: Existing failures identified from previous day, FMEA templates
Deliverables: Completed FMEAs. Applied training for participants on live examples.
Outcomes: Corrective action plans resulting from completing FMEAs. Participants will have the skills and experience in completing FMEAs in a live environment.