FAILURE MODE AND EFFECTIVE ANALYSIS

Course Duration

2 Days.

Objectives

This session enable the participants to

• Understand the appropriate Procedures to perform Risk Analysis for a process or design.
  
• Construct the right FMEA table.
  
• Document the FMEA process and transfer to the appropriate Control Plan for manufacturing.
  
• Manage and facilitate cross functional groups in performing FMEA analysis.
  
• Know and appreciate the importance of setting Right Control Plan in ensuring product quality and process capability.
  
• Ensure Product and Process Quality in proactive manner.

Training Methodology

The course will be conducted in the form of workshop, lectures, case studies, practically design the FMEA for participant's application and examples.

Who Should Attend

All personnel involved in R&D, Quality, production and also those in marketing and sales.

Resource Person

Sim Lam Thong has more than 15 years of vigorous experience involvement in TQC/TPM activities, statistical application, problem solving and management training. He possesses a B.Sc. Ed. (Hons.) (Mathematic/Physics) and M.Sc. (Taguchi Experimentation) both from USM, Penang. He has also been consulting for many multinationals such as Hitachi Semiconductor, ICI Products, Hewlett Packard, Seagate Prai and many local companies such as Daibochi (M) S/B, Acer Computers, B.Braun Medical and more. He specializes in quality, TQC, SPC, productivity and TPM training/consultation, industrial statistics application and design of experiment training and implementation.

Contents

General Introduction

• The worldwide effort of re-engineering
  
• Global competitive in business development
  
• Customer's requirement, audit and quality improvement
  
• The quality and reliability aspects of products.
  
• Basic definition of risks associated with a product, design and process
  
• Tools for assessing and remedying risks

FMEA Methodology

• Different types of approach in managing a process
  
• Risk Analysis of a process/design
  
• Process Flow Charts
  
• Design and Process FMEA

Tool that can be applied while doing FMEA Studies

• Identifying root causes
  
• Problem solving techniques
  
• Analyzing and writing operating/manufacturing procedures
  
• Poka Yoke (Mistake Proof) Methods

Design FMEAs

• The arts of identifying failure methods
  
• Risks on failures of products
  
• Measures of severity, frequency and detection
  
• Interaction effects
  
• Design controls
  
• Examples and workshop on design analysis based on your company's product application and customer's requirement
  
• Roles and responsibilities of every member in Design FMEAs
  

Process FMEAs

• Identifying process failure modes
  
• Assigning severity, frequency and detection ratings
  
• Process Control Guidelines
  
• Examples of Process FMEAs
  
• Workshop on real life process FMEA applications

Transferring FMEA results to Control Plan

• Example of control plans
  
• Regular audit procedures
  
• Exercise and workshop

Linkage between FMEA and QFD

• What is QFD?
  
• When, Where, Who, How, What and Why of QFD
  
• General examples

General Discussion

• Composition of FMEA Team & member's roles and responsibility
  
• Managing team and maintaining team morale
  
• General discussion