Failure Modes & Effects Analysis (FMEA)

Course Description
FMEA (Failure Modes & Effects Analysis) is a powerful tool used to assess, manage, and reduce risk associated with failure or potential failure of products, processes, services, and other systems. Quality Support Group’s FMEA course is designed to help participants evaluate potential failure modes for processes and their likely effect on outcomes and/or product performance. Once failure modes are established, risk reduction can be used to eliminate, contain, reduce, or control the potential failures. The output/results of FMEA can also be used as a basis for design, for further analysis, or as a guide for resource deployment.

Who Should Attend
The ability to predict and evaluate potential failure modes is crucial. Whether you work in a complex engineering and manufacturing environment, or a process-oriented one, such as a hospital, laboratory or school system, this course will benefit you.

Learning Objectives
This course will give participants a clear understanding of how and when to implement FMEA. Using hands-on exercises and real world examples, students will learn to:

  • Determine the right time to initiate FMEA
  • Identify and classify potential failure modes
  • Build a cross-sectional team qualified to perform FMEA
  • Evaluate potential failure mode severity and probability
  • Utilize “bottom-up” analysis to evaluate a failure mode effect in order to uncover the cause
  • Maximize FMEA as a flexible tool to meet your industry or product-specific needs

Course Outline
Introduction to FMEA
This session begins with student and instructor introductions and a review of the workshop agenda and objectives. Students are introduced to Failure Modes and Effects Analysis (FMEA) as a powerful prevention technique. Specific training topics include:

  • FMEA fundamentals
  • Determining the right time to initiate FMEA
  • Identifying and classifying potential failure modes
  • Potential Design/Process failure modes
  • Potential effects of failure
  • Severity: evaluation criteria
  • Potential failure causes/mechanisms
  • Occurrence: evaluation criteria
  • Current Design/Process controls
  • Detection: evaluation criteria

Core Team
Students learn to build a cross-sectional team qualified to perform FMEA and integrate the FMEA process in their work as a value-added tool. This session includes training on the following skills and tools, necessary to effectively apply FMEA within an organization and support that organization’s commitment to continually improve its products, processes, services, and other systems:

  • Evaluating potential failure mode severity and probability
  • Utilizing “bottom-up” analysis to evaluate a failure mode effect to uncover cause
  • Maximizing FMEA as a flexible tool to meet industry or product-specific needs
  • Identifying failures that have unwanted effects on system operation

Risk Priority Number (RPN)
Students learn to assign potential failure ratings for the likelihood of failure (occurrence), severity of failure (severity), and the likelihood of such a failure being detected (detection). The product of these three numbers forms a risk priority number (RPN), which indicates any high-risk failures so that preventative action can be taken. This session includes a discussion of recommended actions for resulting RPNs.

FMEA Exercise
The key output from this session is a completed FMEA. Students gain practical experience by applying FMEA to assess, manage, and reduce risk associated with failure or potential failure of a specific product/process. This Exercise includes the following training activities:

  • Identifying and eliminating potential product/process failure modes
  • Prioritizing product/process deficiencies
  • Capturing engineering/organization knowledge
  • Documenting risk and actions taken to reduce risk
  • Providing focus for improved testing and development

Course Format
16 hours
Combination lecture and classroom exercises
Available at QSG’s training facilities and on-site at your organization

Course instructors:
Angelo Scangas – President and CEO
James F. Leonard – Senior Consultant, Process Improvement and Statistical Methods
Laura Halleck – Senior Consultant, Quality Systems Auditing (Automotive, Aerospace)
Ed McFayden – Consultant, Quality Systems, Lean Six Sigma, Auditing
Saleha Yusof-Mullenix – Consultant, Lean Six Sigma

FREE FMEA Resources!

Course Evaluations Set 1
Course Evaluations Set 2 

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