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Training

Trust the Process

APQP Training Program

Advanced Product Quality Planning is the framework of procedures and techniques used to develop products. Test.

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DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and...

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DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design....

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PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the...

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PPAP Training Program

Production Part Approval Process is a standardized process in the automotive and aerospace industries that helps manufacturers and suppliers communicate...

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DFM/A Training Program

Design for Manufacturing and Assembly is a combination of two methodologies; Design for Manufacture, which means the design for ease...

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DMAIC Training Program

Lean Six Sigma – A structured and disciplined approach to making fact-based decisions that cover the DMAIC phases: Define; Measure;...

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DOE Training Program

Design of experiments (DOE) – provides a systematic method to determine the relationship between factors affecting a process and the...

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Reliability Engineering Training Program

Reliability Engineering describes a focused approach to complete Reliability Engineering methods and how they will benefit your organization

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ISO 26262 Training Program

Functional Safety describes how to implement a vehicle level functional safety program, create a HARA, and understand the interactions within...

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MSA Training Program

Measurement System Analysis is an experimental and mathematical method of determining how much the variation within the measurement process contributes...

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SPC Training Program

Statistical Process Control is a scientific visual method used to monitor, control and improve processes by eliminating special cause variation...

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FTA Training Program

Fault Tree Analysis is a systematic, deductive (top-down), graphical methodology for defining a single specific undesirable event and determining all...

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MFMEA / DFM M&T Training Program

Machine Failure Modes and Effects Analysis is a methodical approach for identifying all possible equipment failures in a manufacturing or...

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RCA Training Program

Root Cause Analysis – 8D is a methodical problem-solving process that covers the three common stages of correction: ⦁ Act...

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QSB Training Program

QSB will provide a summary of how to assess shop floor manufacturing systems. Training will include control of nonconforming products,...

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Poka-Yoke Training Program

Poka-yoke is a technique for avoiding simple human error in the workplace. Also known as mistake-proofing, goof-proofing, and fail-safe work...

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Process Awareness

Ability and knowledge to participate in  completing the FMEA Process

LEVEL 1

Competency

Ability and knowledge to lead a team in the FMEA Process

LEVEL 2

Proficient

Ability to teach and mentor Participants and Team Leads in the FMEA Process

LEVEL 3

Expert

Ability to lead an organization implementing FMEA

LEVEL 4

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DFM/A Training Program

Design for Manufacturing and Assembly is a combination of two methodologies; Design for Manufacture, which means the design for ease...

Learn More »

PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the...

Learn More »

DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design....

Learn More »

DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and...

Learn More »

Please visit ReliatrainGov.com for more information about Government Services

PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the...

Learn More »

DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design....

Learn More »

DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and...

Learn More »

Please visit ReliatrainGov.com for more information about Government Services

DFMEA – FMECA Training Program

Design Failure Modes and Effects Analysis (DFMEA)
Failure Modes, Effects and Criticality Analysis (FMECA)

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COURSE DESCRIPTION

Design Failure Modes and Effects Analysis (DFMEA) is defined as a core tool used to identify the potential failures (risk) of a design not performing its intended function and define controls and actions to address the potential risks of failure. DFMEA is the analysis of design engineering decisions for systems, subsystems, interfaces, and/or components to perform the intended function(s) over the intended life. The process output is focused on defining actions to address design-related deficiencies, with emphasis on improving the design (making the design more robust) and improving (supplementing) the design verification plan (DVP).

Some organizations conduct Failure Modes, Effects and Criticality Analysis (FMECA) in place of DFMEA but they are both considered reliability risk assessment techniques used to identify ways a product can fail to meet defined requirements. This course will define the similarities and differences between the two processes and they will both be defined within the Six Step Process.
The DFMEA and FMECA methodologies are interactive processes consisting of 6 steps: 1) Planning, 2) Preparation, 3) Technical Risk Analysis, 4) Risk Assessment (Calculate and Prioritize), 5) Reduce Risk (Actions and Risk Reassessment), and 6) Communicate Risk (Audit, Feedback, and Follow-up Loop). This course defines how each process step supports engineering decisions and the development of robust designs.
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 FMEA/FMECA standards (e.g., SAE J1739, AIAG FMEA Fourth Edition, MIL-STD-1629A, SSSP30234, AIAG-VDA FMEA Handbook).

COURSE OBJECTIVES

This training program is intended to provide an introduction and foundation of the Design Failure Modes and Effects Analysis (DFMEA) or Failure Modes, Effects and Criticality Analysis (FMECA) based on defined industry standards and requirements. Mastering the content will improve product quality, reliability, and launch effectiveness. At the end of this course you should be able to:

• Define when and why DFMEA or FMECA is required during the Planning phase
• Define the relationship of DFMEA or FMECA in Systems Engineering, APQP, and PPAP
• Define the relationship of DFMEA or FMECA with DFM/A methodology
• List Preparation documentation necessary to complete DFMEA or FMECA
• Describe how functions and requirements are inputs within the DFMEA or FMECA Problem Analysis process
• Describe the difference categories of failure modes
• Describe the relationship between a failure mode, effects of failure and causes
• Use DFMEA to help identify and address product special characteristics
• Define the difference between prevention and detection controls
• Define the relationship between DFMEA or FMECA and Design Verification Plan (DVP)
• Define the relationship between DFMEA or FMECA and Survivability analysis
• Define the Risk Calculation process for DFMEA or FMECA
• Describe how to Reduce and Manage Risk and when actions are necessary
• Define the relationship between DFMEA or FMECA and PFMEA
• Define the roles of both management and engineers within the DFMEA or FMECA Process
• Define the importance of the Audit, Feedback and Follow-up information to the DFMEA or FMECA team and organization
• Define how DFMEA is associated within QMS and IATF-16949:2016
• Define how Monitoring and System Response (MSR) is associated with DFMEA

COURSE OUTLINE

The course eliminates bottlenecks and process inefficiencies by comprehending industry best practices and organizes them into a disciplined and logical 6 Step DFMEA / FMECA Process which includes:

• Planning
• Preparation
• Technical Risk Analysis
• Risk Assessment (Calculate and Prioritize Risk)
• Reduce Risk (Actions and Risk Reassessment)
• Communicate Risk (Audit, Feedback, and Follow-up Loop)

Step One: Planning

The planning phase supports the definition of the product content (systems, subsystems, and components) that requires analysis. Participants will receive example criteria and modifiable templates they can use to evaluate any product to determine the DFMEA / FMECA scope and cross-functional team. The following are elements of Step One:

• Define the “Voice of the Customer” (Requirements)
• Define Product (System, Subsystem, Component, etc.)
• Define Current Issues (e.g., Field, Test, Supplier Issues)
• Define DFMEA/FMECA Plan - (Design Risk Level / Novelty)
• Define and Train the Team

Step Two: Preparation

The preparation phase makes the design and design requirements visible. Included are modifiable templates and examples that organizations can use to ensure internal and external stakeholders have a road map to develop a robust design without any hidden requirements. The following are elements of Step Two:

• Define Usage Profile (e.g., Environment)
• Define Product and Interfaces (Boundary Diagrams)
• Define Functions
• Define P-Diagram
• Define Current DVP (Design Verification Plan)
• Define known Guidelines and Best Practices
• Define review process to proceed to analysis phase

Step Three: Technical Risk Analysis

The assessment phase provides a step-by-step process for the relevant engineer and FMEA Team to complete assessment of the design. Various technical reviews require different experts that can uncover hidden design deficiencies. The linkage and collaboration with the interfacing processes will yield a robust design. The following are elements of Step Three:

• Preparation information provides the FMEA foundation for DFMEA (Mechanical, Electric Software) or FMECA
• Level of analysis (Item/Element) is defined based on system, subsystem, or component
• Functions and requirements are assigned for each element of analysis
• Failure modes, effects, and causes are defined for each element of analysis
• Prevention and Detection controls (Guidelines, Best Practices, etc.) are defined with input from DVP

Note: The following interfacing technical reviews support the technical risk analysis phase:
• Monitoring and Systems Response (MSR)
• Design Reviews Input
• Fault Tree Analysis Input
• Design for Manufacturing and Assembly Input
• Survivability analysis input
• Process Integration (PFD, PFMEA, PCP, etc.)
• Design Verification Plan (DVP)
• Management Review and Approval to Proceed

Step Four: Risk Assessment (Calculate and Prioritize Risk)

Based on the type of analysis, DFMEA or FMECA, associated risk calculations will be completed. The following are elements of Step Four:

• Risk Calculation (Ranking)
• Definition of Critical/Special Characteristics

Step Five: Reduce Risk (Actions and Risk Reassessment)

DFMEA has little value unless the recommended actions are fully executed and decisions are made based on actions results and reassessment of risk. The following are elements of Step Five:

• Actions and Actions Results
• Reassessment of Risk
• Confirm Supplier Actions Results
• Confirm Process Integration
• Cross-functional Team and Management Review

Step Six: Communicate Risk (Audit, Feedback, and Follow-up Loop)

It is recommended the responsible engineer (or team) or a third-party complete an audit of the DFMEA or FMECA. The results of the DFMEA or FMECA and the audit should be shared with the organization and the customer or appropriate suppliers. The following are elements of Step Six:

• DVP Updated
• Audit of the DFMEA or FMECA and Process
• Results of DFMEA or FMECA and Audit feedback to organization
• Results of DFMEA or FMECA feedback to customers and suppliers
• Development or update of lessons learned, guidelines and best practices
• Celebrate with the team!

Throughout the training, the participant will be required to take various quizzes that test proficiency. At the end of the training the participant will also be required to complete a course survey based on the course material and the instructor. ReliaTrain uses the results of the quizzes and surveys to update the training to provide the best experience to participants.

COURSE PREREQUISITES

This is a Level One foundation training module and does not have required prerequisite training or experience. However, this course is a Prerequisite for higher level (Competency, Proficient, and Expert) FMEA Certification.

COURSE RECOMMENDED PARTICIPANTS

DFMEA / FMECA training supports the roles of Product Design Engineers, Safety Engineers, Reliability Engineers, Software Engineers, Materials and Fasteners Engineers, Maintenance / Service Engineers, Test Engineers, Manufacturing Engineers, Quality Engineers, Supplier Quality, Chief Engineers, FMEA Facilitators, Logistics, Management, and Aftermarket Engineering [Including Suppliers].

This DFMEA / FMECA training program is intended for all industries including but not limited to:

Commercial
Medical
Utilities
Aerospace
Consumer Lifestyle Products
Civil Engineering
Tooling and Equipment
Oil and Gas
Trains & Railroad Equipment
Military [DOD]
Government
Phones & Personal Devices

This course supports companies that use SAE J1739 FMEA Standard, AIAG FMEA Fourth Edition, MIL-STD-1629A FMECA (Section 101 FMEA), SSP30234 (NASA), AIAG-VDA FMEA Handbook, or want to develop a company specific process to complete DFMEA or FMECA. DFMEA and FMECA are reliability assessment techniques recommended and outlined in SAE Reliability Handbook TA-HB-0009 and SAE JA1000.

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 0.9 CEU’s towards their professional certification.