Failure Mode & Effects Analysis and Control Plans

1 Day Course, 8 Hours

Course Overview

The current international quality systems such as ISO 9001 and ISO/TS 16949, require the use of statistical methods for continuous quality improvement. One of the approved methods is FMEA. FMEA is an analytical method used to identify potential modes of failure in a product or process and the subsequent effects the failure might cause. FMEA enables the designing of quality into the product, instead of inspecting or testing it in. By classifying failures in terms of how critical they are, it establishes priority for corrective actions. Therefore, it can actually accelerate the design and development process.

This seminar also covers basic issues related to product liability and product reliability calculations, which are an important requisite for an effective FMEA. The emphasis is upon concepts and techniques, with minimal mathematics.

Another important requirement of ISO/TS16949 is the implementation and use of Control Plans. Control Plans are the working documents used in Production and Service to facilitate the effective control of critical quality points.

This course clearly shows the functional link between FMEA and the development of comprehensive Control Plans.

The FMEA course covers the following topics:

  • Failure distributions and safety margin
  • Issues of product liability and the rudiments of reliability
  • Factors affecting quality
  • Block diagrams and flowcharts
  • Design FMEA
  • Process FMEA
  • Control Plans

Learning Objectives

  • Understand product liability and reliability
  • Calculate probability of survival and mean life
  • Calculate safety margin for product designs
  • Understand and apply FMEA for products and processes
  • Create Control Plans that are led by PFMEA findings
  • Relate FMEA and Control Plans to the requirements of ISO Standards

Target Audience

FMEA is particularly well suited for product designers and engineers. Other professions that will find FMEA beneficial are, but not limited to: manufacturing engineers, quality engineers, and other production persons. Service organizations can also gain significant improvement from its implementation; examples are included in the presentation. Managers of these functions will benefit greatly.

Textbooks

  • AIAG publication “Potential Failure Mode and Effects Analysis” – FMEA 4th Edition