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.

Prerequisites:

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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