Failure Mode & Effect Analysis

Failure Mode Effect Analysis is the primary tool used in industry to assess risk both at product design and development stage, and during manufacturing. The overall objective of the analysis is to ensure that the product delivered to the customer is free of defects and will perform to specification. Risks of failure are assessed during analysis. A thorough assessment of potential failure modes and their associated causes/mechanisms will be undertaken in a FMEA, leading to appropriate actions to eliminate as far as possible the failure modes and their corresponding effects. FMEA’s can be complex, so good cooperation and coordination is required within the FMEA teams, and it is important that the analysis is conducted in a carefully structured manner to assure that the work is done efficiently and effectively. Ideally, all team members will have the same understanding of the FMEA process, and are trained to follow a well-structured procedure.

Delivery Mode

  • Public
    Programmes

    Dates
    05 Nov 2024
  • Virtual
    Training
    Programmes

    Contact Us
  • Customised
    In-Company
    Programmes

    Contact Us

SnapshotSnapshot

Course Code
CPI005

What's covered?

The training course is presented both on a public basis and in-company. For the practical-work session described below, the tutor provides a comprehensive case study for the public course. For in-company courses the participants will undertake the analysis of failure modes chosen from their own work environment.

Introductory Session
In the introductory session the tutor will use a real FMEA case study to explain in detail the procedure to be followed when undertaking the analysis and how FMEA is used to assess risk at product design and manufacturing stages. This includes the steps to be followed in determining the Risk Priority Number (RPN) and examples of actions taken to eliminate/reduce the risk of failure. The tutor will provide a detailed step by step procedure for the teams to follow in the practical session. The introductory session will include discussion on:

  • Design and Process FMEA’s
  • Forming the FMEA team and utilising effective brainstorming techniques
  • Development of a design FMEA and a process FMEA.
  • Identification of the causes and effects of failure.
  • Determining and understanding the Risk Priority Number.
  • The benefit of effective corrective actions in reducing the RPN.

Practical Team Exercises
Most of the day will be devoted to a practical team exercise. The teams will work from first principles through the steps of analysing failure modes following the procedure provided by the tutor. The tutor will act as facilitator during this session.

Who should participate?

  • Product, process, design, and R&D engineers and scientists
  • Quality engineers and scientists
  • Production management

What will I learn?

Participants achieve the following learning outcomes from the programme;

  • Conduct FMEA analysis
  • Participate in FMEA teams
  • Lead FMEA teams
  • Demonstrate understanding of the structure of FMEA analysis which leads to the satisfactory elimination of the causes of failure modes

Who are the tutors?

Albert Plant

With a background of thirty year’s practical experience, Albert Plant is Ireland’s leading trainer and consultant in the application of statistics.  Combining degrees in Engineering and Statistics, he brings a unique blend of a deep understanding of manufacturing technology with expertise in all aspects of statistical data analysis to his training courses.  Attendees on Albert’s training courses include people, many with PhD’s, undertaking the most advanced research and development in pharmaceuticals, medical devices, nanotechnology, and other leading-edge specialities, who require statistical skills to understand the outcome of their research work.

Many customers require that the training courses be customised, and Albert has developed a high level of expertise in meeting this requirement.  His In-House courses typically incorporate company data, and both the length and content of the courses are agreed in advance with the customer, to meet very specific needs.

Minitab is the leading brand of general-purpose statistical software. Albert has used Minitab in his training and consultancy work for more than 25 years.  He proposed to the Minitab company that they introduce a module in Acceptance Sampling, and he contributed to the early development of the module, which was launched with new versions of the software in 2006.  Albert also has expertise in other statistical software, such as Design Expert, which he uses in Design of Experiments.


Grainne Heneghan

Grainne is a highly experienced Continuous Improvement and Lean Six Sigma Master Black Belt with over 20 years’ experience in the global IT industry.

Grainne has many years of experience of developing and delivering training and working with Quality and Lean Six Sigma methodologies, tools and techniques, with focus on improving processes, reducing waste and decreasing costs for teams and organisations. She is resourceful and adaptable and uses strong communication and interpersonal skills along with metrics, data and logic to ensure that teams achieve their goals and successfully implement change within their organisations.

Grainne has trained and coached many Yellow, Green and Black Belt students to successful certification. Along with many years training in a traditional classroom style, she spent 4 years training using an online Virtual Classroom while working at Hewlett Packard. This included virtual training in Minitab and Statistical Concepts alongside softer skills such as Brainstorming for Root Cause Analysis and How to Complete FMEAs. She likes to blend her efficient organising skills and strong attention to detail with a softer empathetic and practical approach to projects. She is open-minded with a holistic and positive approach when working with teams.

Grainne enjoys working with teams and training students to use and to get the most from tools such as Minitab, and other statistical methods and techniques.


How do we train and support you?

In-House Courses
For In-House courses, the tutor will contact you in advance to discuss the course programme in more detail in order to tailor it specifically for your organisation. On practical team exercises, participants will be grouped in small teams and they will undertake analysis of failure modes selected from their own processes, following a detailed procedure provided by the tutor. The tutor will act as facilitator for the teams.

Course Manual
Participants will be provided with a very comprehensive course reference manual, which explains in detail how to undertake a FMEA. The manual includes a fully worked FMEA as an example. The worked examples will provide useful references for the participants undertaking FMEA when they return to their workplace.

Grainne Heneghan

Duration: 1 day
Hide

Grainne Heneghan

Duration: 1 day
Virtual Training: €395
Hide
  • 05 Nov 2024
    Delivery: Virtual Training
    Location: Virtual
    Book Date

Contact SQT today