RELIABILITY ENGINEERING

2020
TRAINING SERIES

FMEA Advanced
Failure Mode and Effect Analysis

OPEN & IN-COMPANY TRAINING

Languages: Portuguese, Spanish or English
Open Price: Make Contact (Up to 10 places available) “ IN HOC SIGNO VINCES “
In-Company Price: Make Contact (Up to 20 Person)
Length: 24 hours (3 Days)
Contact: business@whyconsultoria.com

WHY CONSULTORIA LTDA – Avenida Raja Gabaglia, 1001/602A – CEP 30.380-403 Luxemburgo – Belo Horizonte – MG – Brasil
Tel: (31) 2514-0924 / (31) 98878-8008 Vivo / (31) 98332-8900 Claro – CNPJ: 27.220.587/0001-09 IE: Isento IM: 1.017.819/001-X
RELIABILITY ENGINEERING – TRAINING SERIES

Management Dilemmas

QUESTIONS?
o Why and How the things fail?
o How much a failure cost?
o How many failures will occur next year?
o How many spare parts will you need next year to supply the warranty?
o How can you more quickly solve the problem caused by a failure?
o What could you have done to avoid failures?

ANSWERS!
✓ You need to know the causes of failures!
✓ You need to know the probability of occurrence of failures!
✓ You need to know the consequences of failures!
✓ You need to know the behavior of failures!
✓ You need to know how to conduct a financial analysis of the failure!
✓ You need to know how to implement effective action plans!

Don´t you know how to do it? Ask WHY?

WHY Consultoria has the answer!

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RELIABILITY ENGINEERING – TRAINING SERIES

FMEA Training Description

FMEA training, Failure Mode Effect Analysis training provides the
concepts needed to effectively prevent industrial product failures.
FMEA Training covers the methodology to perform Failure Mode
and Effect Analysis, an introduction to Life Data Analysis (LDA)
and other hot topics currently in many engineering areas.
FMEA Training also includes design and process troubleshooting
guidelines, which are needed to perform problems found in most
production facilities. Failure Mode and Effect analysis helps you
to identify what, how and why something happened, thus
preventing recurrence. The Failure Modes can be controlled by
management and allow recommendations.
Failure Mode and Effect Analysis is a powerful tool you can uses to
focus on the cause of the equipment failure to prevent future
failures.
Learn the techniques and methods to developing effective
recommendations, data collection, charting, cause identification
and recommendation generation and implementation.

By end of this training, you will be able to:

• Identify common design and manufacturing errors and
deviations
• Identify the Failure Mode and figure out what to do to reduce the
likelihood that it will happen again
• Learn to make and use Preliminary Risk Matrix
• Learn when to use cause and effect Fishbone (Ishikawa) diagram
• Assess how to make FMEA as a team based, analytical approach
• Gain real world skills on effective methods for critical thinking,
creative solutions and corrective actions
• How to use data collection to model the failure modes and
recommendation generation and action plan implementation

Who Should Attend

Engineers, Technician, analysts, Production supervisors,

production lead personnel, quality engineers, manufacturing
engineers, maintenance engineers, manufacturing
managers, process engineers, design engineers should attend
this training.

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RELIABILITY ENGINEERING – TRAINING SERIES

Objectives Outline

FMEA - Failure modes and effects analysis

• FMEA Overview, Objectives and Implementation Reasons

• FMEA Definition and Standards
• DFMEA, PFMEA and other types of FMEA
• FMEA Implementation Prerequisites and Strategy
• Roadmap for Analysis
• How to Ordering the ideal analysis team
• Analyze the data: Introducing the hierarchy tree
• Identification of Function, Failure, Effects and Failure Modes
• Generating Fault Tree (FT) from FMEA
• FMEA Data Mining
• Failure Mode evaluation and statistics
• Measuring Risk (RPN)
• Prioritizing Actions (S, SO and SOD Pareto Chart)
• FMEA Basic Rules
• FMEA Success Factors and Detail Level
• FMEA Facilitation and Skills
• Generic and Specific FMEAs
• FMEA for Suppliers
• Decision making Matrix
• FMEA and PDCA Cycle
• FMEA Risk recalculation and Revisions
• FMECA Failure Mode and Criticality Analysis
• DRBFM Design Review Based on Failure Modes
• APQP Advanced Product Quality Planning
• DVP&R Design Verification Planning and Report
• FMEA Misconceptions and Objectives by Carl Carlson
• FMEA Facilitation and Audits

LDA - Life Data Analysis (Basics)

• LDA Goals
• What is Reliability Engineer
• Reliability versus Cost Analysis
• Failure Rate Behavior and Bathtube chart
• Modeling Reliability Data
• Statistical Distributions
• Exponential, Normal, Lognormal and Weibull Distribution
• Estimation Methods (Linear Regression and MLE)
• Confidence Limit

FA – Financial Analysis

• Failure Cost
• Financial Math
• Compound and Simple Capitalization
• Cash Flow (Simple and Discounted)
• Financial Equivalence
• Interest and Interest Rate
• Economic Evaluation Indexes (Pay Back, NPV, IRR, EAV, EAC and ROI)

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RELIABILITY ENGINEERING – TRAINING SERIES
AP – Implementing FMEA Action Plan

• Action Plan (5W2H e 8D)

• Defining Plan Scope
• Dividing Plan into Tasks (WBS and OBS)
• Sequencing the Tasks and Estimate Task Duration
• Developing Task Scheduling
• Managing the Plan Scope, Time and Cost.
• Corrective action definitions
• Corrective action order of precedence (Pareto Analysis)
• Advantages and disadvantages of design modifications, process
modifications, procedural modifications, requirements relaxation,
screening, and other potential corrective actions
• Evaluating corrective action effectiveness. Inspection caveats
• Corrective Action Requirements.
• Material review, disposition, and corrective action

Conducting a Cost-Effective Failure Mode and Effect Analysis

• Nominate a FMEA facilitator

• Choose a FMEA team leader
• Develop a FMEA reporting
• Make a Financial Analysis and Corrective Action Plan
• Nominate Person(s) Responsible
• Action Due Date Measurement Technique
• Establishing a Value Criterion
• Pick a Failure Mode
• Calculate Cost-effectiveness
• Growth potential
• Practice Description
• Opportunities for Impact
• Evidence for Effectiveness of the Practice
• Potential for Harm
• Costs and Implementation
• Automating FMEA
• Requirements for Analyzing Failure Modes and Their Effects

Strategies and Solutions for Failure Mode and Effect Analysis

• Process is the key

• Tools and techniques are essentials
• Technique and tools to develop and implement effective and efficient
FMEA programs
• Tools and techniques to identify design and manufacturing errors
• Tools and techniques to trouble shooting
• Addressing the challenges of FMEA investigations
• Tools and techniques for identifying common Failure Modes and
implementing corrective actions
• Design, Manufacturing and Maintenance Investigations techniques
• Managing corrective and preventive action plans

FMEA – FAILURE MODE AND EFFECT ANALYSIS 5