Failure Modes and Effects Analysis for Process Design and Improvement One-day Workshop

Learn the best approach understanding process failure and prevention

Course Description

Course Number FMEA–001: Failure Modes and Effects Analysis (FMEA) for Process Design and Improvement: Understanding process failure and prevention

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Failure Modes and Effects Analysis (FMEA) for Process Design and Improvement One-day Workshop

This one-day workshop takes a holistic approach to preparing you to analyze and prioritize process failure risks and prevent them from happening. FMEA is a hands-on workshop that leads you through the complete process of defining the important outcomes to a process, anticipating risks, and developing implementation strategies to assure their robustness. Students learn the objectives and applications of FMEA, and why, when, and how to apply it. Two workshop projects — one with the aid of a simulated process and one with the participants own process — assure that students learn by doing and are prepared to go back and work successfully with their colleagues to implement FMEA.

Course Topics:

  • Prepare for an FMEA by defining the priority process outcomes, developing process maps, identifying critical to quality (CTQs), and critical to process (CTPs) variables at each step.
  • Team-up for successful FMEA efforts.
  • Conduct the FMEA in an efficient and effective manner.
  • Follow-up to lower failure risks.
  • You will leave the workshop with a head-start on applying FMEA to a process you select from your operations back home.

Day 1: Introduction to FMEA and part 1 — Simulation workshop

  • Origins, objectives, and types of FMEA and how FMEA works.
  • Preparing for a successful and meaningful FMEA with the team and inputs.
  • Workshop 1 for Simulated Process — part 1.
  • Defining the FMEA objectives.
  • Outlining the process with an SIPOC.
  • List and prioritize customer requirements.
  • Develop and prioritize CTQs and CTPs per Kano categories.
  • Conduct first FMEA.
  • Develop strategies to lower Risk Priority Numbers (RPNs).
  • Run FMEA for selected process steps.
  • Summarize and review FMEA results and next steps.
  • Conclude and summarize takeaways.

Course Objectives:

Upon completion of this one-day course, participants will have a foundation for understanding process failure and prevention.

What career paths benefit the most from Design and Analysis of Experiments for Continual Improvement of Processes and Products Workshop?

  • People working with manufacturing or non-manufacturing processes.
  • Manufacturing, process and quality managers, and engineers.
  • Product and process development and design engineers.
  • Continual improvement and process excellence program managers.
  • Participants in process and quality improvement teams.

Additional Course notes:

While the focus in this workshop is on Process FMEAs, the instructor will comment and assist on the application of the FMEA methodology to System and Product Design FMEAs.


There are no prerequisites for this workshop. Participants benefit most by arriving at the workshop with a specific process in mind to which they would like to apply the methodology.

Credit and Follow-up:

Recommended follow-up workshops include: “Intro to Statistical Methods”, “Statistical Process Control”, and “The Visual Workplace”.

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