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
DFMEA – FMECA Training Program
Design Failure Modes and Effects Analysis (DFMEA)
Failure Modes, Effects and Criticality Analysis (FMECA)
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).
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
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:
• 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)
|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)
|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
Note: The following interfacing technical reviews support the technical risk analysis phase:
|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)
|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
|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
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.
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:
Consumer Lifestyle Products
Tooling and Equipment
Oil and Gas
Trains & Railroad Equipment
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.