GEMBA KAIZEN TRAINING INSTITUTE

Design Failure Mode & Effects Analysis Training
(DFMEA Training)

DFMEA, or Design Failure Mode and Effects Analysis, is typically used in the early stage of the product lifecycle and development as a troubleshooting and assurance process and tool.

Design FMEA training helps design engineers, verification engineers, and project/product managers to proactively analyze, investigate, troubleshoot and uncover potential failure, quality, performance, and safety and hazards issues.

Failure Mode and Effects Analysis (FMEA) is defined as a regular technique used to inhibit failure. Such action is conducted through the exploration of potential failure modes and the reasons can cause such failure. FMEA actions occur within a team activity by tackling high severity, high occurrence, and high detection rankings that is determined by the analysis. Only through the preventive process of FMEA we can assure the product performance is satisfactory and the chance of the product failure is reduced. The Design FMEA training course will help you explore these steps in detail and learn how to put them in action to prevent the system failure.

Benefits
 What Design Failure Mode and Effects Analysis (DFMEA) is
 How Design Failure Mode and Effects Analysis (DFMEA) is related to Failure Mode and Effects Analysis (FMEA) and Process Failure Mode and Effects Analysis (PFMEA)
 Benefits of Design FMEA
 How to uncover opportunities to prevent failure proactively prior to the failures
 How to collect data and information as part of DFMEA Pre-Work
 How to use DFMEA to investigate and treat risk as actual failure including high severity Failure Modes
 Design Failure Mode and Effects Analysis (DFMEA) process and tools
 Learn about Design FMEA input and output including RPN, severity, occurrence, and detection rankings
 Learn about Requirements, Potential Failure Modes, Effects of Failure and Severity Ranking, Causes, Prevention Controls, Occurrence and Class Column, Detection Controls, calculating the Risk Priority Number (RPN) and more
 Select an Effective DFMEA Cross Functional Teams (CFTs) in your organization
 Analyze your process and plan Cross Functional Teams (CFTs) activities and control
 Plan Design Verification Plan & Report (DVP&R)
 Map design reviews to FMEA Outputs
 Use problem solving activities such as 8D to DFMEA input and output
 Use Design of Experiments (DOE) in conjunction with DFMEA
 Use other tools such as Why-Why, Fishbone Diagrams, Fault Tree Analysis (FTA), 8D, DOE to enhance your Design FMEA activities

Audience
The DFMEA training is a 2-day course designed for:
 Engineers, scientists, and managers involved with manufacturing
 Production and manufacturing team
 Product design personnel
 Reliability, testing, and quality team members
 R&D personnel
 Product and process assurance people
 Assembly personnel

Overview of FMEA and DFMEA/Design FMEA
 Introduction to Failure Mode and Effects Analysis (FMEA)
 Definition of FMEA
 How FMEA works
 Why and where using FMEA
 System/Subsystem/component Design FMEA
 Manufacturing and Assembly Process FMEA
 Machinery and Equipment FMEA (Logistics Support)

Purpose of an FMEA
 Identifying potential risks
 Prioritizing the risks
 Developing an action plan to reduce the risks

Design-FMEA vs. Process-FMEA
 What is DFMEA?
 What is PFMEA?
 Difference between DFMEA and PFMEA?
 When to use which?
 Special features (critical and significant)
 Cooperation on special features
 Characteristics as inputs to PFMEA

Principles of DFMEA/Design-FMEA
 What Is A Design FMEA?
 Identifying potential or known failure modes
 Corrective and preventive actions
 Disciplined analysis of the product/system design
 Design-based failure modes
 Design FMEA steps and flow
 Examples
 DFMEA Development Methodology
 Scope
 Clarify your scope
 How to use the DFMEA Scope Worksheet
 Procedure
 Step-by-step directions of a Design FMEA
 How to use the FMEA Analysis Worksheet
 How to customize the Severity, Occurrence, and Detection Ranking Scales
 Failure Mode Avoidance FMA /FPA Failure Prevention Analysis
 Team structure and rules for efficiency - cross functional teams
 Control Plan
 Some tips on DFMEA

FMEA Relations to Process-FMEA
 Scope
 Clarify your scope
 How to use the PFMEA Scope Worksheet
 Procedure
 Step-by-step directions of a PFMEA
 How to use the FMEA Analysis Worksheet
 How to customize the Severity, Occurrence, and Detection Ranking Scales
 Control Plan
 Some tips on PFMEA


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