Course Description

Improve efficiency, reliability and product quality by identifying and preventing process issues before they arise with Process-FMEA.

Process Failure Mode & Effects Analysis (P-FMEA) – 8 to 16 Hours

Failure Mode and Effects Analysis (FMEA) is a structured methodology for anticipating problems and developing controls to prevent causes or detect defects.  While FMEA is most fruitful as a proactive tool used during process development, it can also be effectively applied as a continuous improvement tool after a product launch, and updates to FMEA should happen during problem solving.

Workshop versions are available for AIAG 4th edition or the AIAG & VDA FMEA approach.

This workshop is application-based and engages participants through exercises and discussion.  Exercises can be tailored to actual product processes.  When the workshop is tailored to actual production processes, participants should bring:

• The process flow diagram or work routing for the process under review
• Recent quality metrics (e.g., scrap, rework, FTQ, warranty, etc.)
• Error proofing, gaging and inspection plans
• An actual sample part (as long as size and/or weight permits)

This workshop is appropriate for individuals who are directly involved with the manufacturing line, especially operators, skilled trades, engineers and quality staff.

Training ideally should take place in the manufacturing area under review.  If necessary, it can also be conducted at a suitable off-site location or even virtually.

We also offer two e-Learning modules:

1. FMEA Introduction
2. AIAG & VDA FMEA Methodology

Both of these modules are available at Accendo Reliability.

FMEA drives both proper guidance to the factory floor and continuous improvement efforts for removal of a process’ weakest links.  Additionally, we emphasize error proofing methods so that high-risk failure modes are not just more likely to be detected but are actually prevented.

• FMEAs are developed integrating understanding of customer requirements, error proofing, process control plans and job instructions.
• Utilization of actual quality data means that the FMEA will be an accurate “snapshot” of the current process controls and operating conditions.
• Since FMEAs drive work procedures and instructions used in production, the workshop advocates control of the critical items that have the greatest impact on protecting the customer from defects.
• Development of in-station process controls focus on prevention of internal defects as well as performance toward a goal of Zero Defects to the customer.
• Our approach is fully compliant with the requirements of ISO 9001, IATF 16949 and AS9100.
• Typically delivered as a two-day workshop but can also be presented over three days with the inclusion of Process Control Plan principles or reduced to one day if only awareness of FMEA is required.

This course is available in the following formats:

• Onsite Training: Available for groups wanting an in-person experience
• Live Virtual Sessions: Delivered online with real-time interaction, ideal for remote teams
• Hybrid Approach: Maximize flexibility by blending real-time online interaction with occasional in-person experiences
• e-Learning Modules: Can get new users up to speed with terminology and basic principles of FMEA