Ability and knowledge to participate in completing the FMEA Process
Ability and knowledge to lead a team in the FMEA Process
Ability to teach and mentor Participants and Team Leads in the FMEA Process
Ability to lead an organization implementing FMEA
DFM/A Training Program
Design for Manufacturing and Design for Assembly Process (DFM/DFA)
Design for Manufacturing and Assembly is a structured methodology that uses an analytical approach to Improve Quality and Reduce Cost by Optimizing Product and Process Designs for Enhanced Buildability and Total Customer Satisfaction.
The Vision is to satisfy Vehicle and Manufacturing Requirements for Safety, Function, Performance, Style, Serviceability, Mass, Quality, and Buildability at the Lowest Overall Cost.
Note: While the DFM/DFA process identifies issues (like other risk assessment tools), a key difference is the identification of product and process Ideas to eliminate the issues while balancing cost and improving customer satisfaction. FMEA processes have recognized the benefit of including a function to meet DFM/DFA criteria and guidelines. However, this falls short of meeting the overall objectives of the process. Organizations must define their internal goals and criteria to determine the benefits of implementing the DFM/DFA process.
This training program is intended to provide an introduction and foundation of the Design for Manufacturing and Assembly process. Mastering the content will improve product and process safety, quality, reliability, and launch effectiveness. At the end of this course you should be able to:
• List the inputs and outputs of DFM/DFA process steps
• Explain the advantage of early development and creation of baseline processes
• Define how advance product planning (APQP), DFMEA, and special characteristics are inputs into DFM/DFA process
• Define how Bill of Process is used in the DFM/DFA process
• Define when and how DFM/DFA ideas are verified and implemented in the product and process designs
• Explain how a baseline product and processes are used within the DFM/DFA process
• Explain how to control modifications and changes to the DFM/DFA process
• Explain how information from PFD, PFMEA, and PCP are an integral part of DFM/DFA
• Use DFM/DFA to identify the need for preventive maintenance in manufacturing and assembly operations
• Use DFM/DFA ideas to improve the BOP
• Use DFM/DFA to resolve the daily activity issues within manufacturing and assembly
• Uncover operations within the manufacturing process that could contribute to product issues (warranty, scrap, customer dissatisfaction, etc.)
The course eliminates bottlenecks and process inefficiencies by comprehending industry best practices and organizing them into a disciplined and logical 4 Step DFM/A Process which includes:
• Planning and Preparation
• DFM Workshop and Report-out
• Verification and Implementation of Ideas
• Audit and Feedback Loop
|Step One: Planning and Preparation
The planning phase supports the definition of the product content (systems, subsystems, and components) and process operations that requires analysis. Participants will receive example criteria and modifiable templates they can use to evaluate any product or process to determine the DFM/A scope and cross-functional team. The following are elements of Step One:
• Define the “Voice of the Customer” (Requirements)
Note: The engineer and manager (DFM/A expert as needed) ensure preparation is complete and correct, and then engage the cross-functional team in a technical review of the product and process designs.
|Step Two: DFM Workshop and Report-out
Completing the DFM/A assessment of the product and process designs includes a series of connecting activities. This workshop phase is broken down into 5 detailed sub-steps. The following are elements of Step Two:
• Workshop preparation
Note: The engineer and manager (DFM/A expert as needed) ensure that the technical review of the product and process designs stays focused on the scope. Facilitation is a learned skill in the DFM/A process.
|Step Three: Idea Verification and Implementation
The DFM/A process uses technical reviews to assess ideas in both digital and physical forms. The following are elements of Step Three:
• Complete preparation for idea verification
Note: Idea verification is critical in the DFM/A process. This step documents the improvements in the product and process design based on defined criteria. The results will also identify areas that need continuous improvement.
|Step Four: Audit and Feedback
It is recommended that the process champion or a third-party complete an audit of the DFM/A workshop and report-out. The results of the DFM/A and the audit should be shared with the organization and similar projects. The following are elements of Step Four:
• Audit the results of the workshop
This is a Level One foundation training module and is a Prerequisite for higher level (Competency, Proficient, and Expert) FMEA Certification. The learner should have a basic knowledge of the following:
• Design Failure Modes and Effects Analysis – DFMEA
• Process Failure Modes and Effects Analysis – PFMEA
• Manufacturing / assembly process flow - PFD
• Process Control Plans – PCP
• Bill of Material – BOM and Bill of Process - BOP
COURSE RECOMMENDED PARTICIPANTS
DFM/A training supports the roles of Product Design Engineers, Safety Engineers, Reliability Engineers, Software Engineers, Materials and Fasteners Engineers, packaging engineer, Material Handling, Maintenance / Service Engineers, Test Engineers, Manufacturing Engineers, Industrial Engineers, Quality Engineers, Supplier Quality, Chief Engineers, FMEA Facilitators, Logistics, Management, and Aftermarket Engineering [Including Suppliers].
This DFM/DFA training program is intended for all industries including but not limited to:
Consumer Lifestyle Products
Tooling and Equipment
Oil and Gas
Trains & Railroad Equipment
Phones & Personal Devices
The output of this course meets the objectives of product development processes including: Advanced product Quality Planning (APQP), Production Part Approval Process (PPAP), Systems Engineering and Reliability Planning (e.g., JA1000, MIL-STD-499A, SAE HB0009, SAE AS9100) and ISO-9001:2015 and IATF-16949:2016.
ReliaTrain training modules are designed to meet industry standards and can be modified to meet company specific requirements. This course is offered Online to enable participants to take the training at their own pace and it is available 24/7 over a one-year period. Upon successful completion of this course the participant will receive a "Certificate of Completion" and also 0.9 CEU's towards their professional certification.