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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

PFMEA Training Program

Process Failure Modes & Effects Analysis (PFMEA)
Includes Process Flow Diagram (PFD) and Control Plan (PCP)

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COURSE DESCRIPTION

This training defines Process Flow Diagrams (PFD), Process Failure Modes and Effects Analysis (PFMEA), and Process Control Plans (PCP) core tools used to identify the potential failures (risk) of a manufacturing or assembly process not performing its intended function and define controls and actions to address the potential risks of failure. The PFMEA methodology is an interactive process consisting of 6 steps: 1) Planning, 2) Preparation (Including Process Flow Diagram), 3) Technical Risk Analysis (PFMEA), 4) Risk Assessment (Calculation and Prioritization), 5) Risk Reduction (Actions and Risk Re-Assessment), and 6) Communicate Risk (Including Process Control Plan (PCP), Audit, Feedback, and Follow-up Loop). Organizations must define sustainable PFD, PFMEA and PCP processes that will manufacture and assemble products to defined requirements throughout the product life.

COURSE OBJECTIVES

This training program is intended to provide an introduction and foundation of developing Process Flow Diagrams (PFD), Process Failure Modes and Effects Analysis (PFMEA), and Process Control Plans (PCP). Mastering the content will improve product quality, reliability, and launch effectiveness. At the end of this course learners should be able to:

• Implement Process Flow Diagrams (PFD) in a manufacturing process
• Uncover “hidden factories” and material handling in PFDs
• Describe value added operation steps in PFD
• Use information from PFD to create PFMEA
• Use PFMEA as a tool to identify and mitigate risk in the manufacturing process
• Use PFMEA to determine the need for error proofing within the manufacturing process
• Use PFMEA to determine the need to consider design improvements to resolve potential quality issues
• Use PFMEA to determine the need for preventive maintenance on tooling and fixtures
• Use information from PFD & PFMEA to create Process Control Plans (PCP)
• Use PFMEA and PCP to define quality checks within the manufacturing process
• Use PFMEA and PCP to address special characteristics
• Compare the PFD, PFMEA, & PCP Processes
• Describe the relationship of product and process characteristics within PFMEA and PCP
• Describe the relationship and interplay between DFMEA and PFMEA
• Use PFMEAs to resolve the daily activity issues within manufacturing and assembly
• Define the linkage between PFD, PFMEA and PCP
• Uncover operations within the manufacturing process that could contribute to product issues (warranty, scrap, customer dissatisfaction, etc.)
• Define how to complete PFMEA’s without information from DFMEA’s
• Define how PFD, PFMEA, and PCP are associated within QMS and IATF-16949:2016 requirements

COURSE OUTLINE

The course comprehends the industry best practices and organizes them into a disciplined and logical 6 Step PFMEA process that includes definition and linkage of PFD, PFMEA, and PCP. The process steps include:

• Planning
• Preparation (Including Process Flow Diagram)
• Technical Risk Analysis (PFMEA)
• Risk Assessment (Calculation and Prioritization)
• Risk Reduction (Actions and Risk Re-Assessment)
• Communicate Risk (Including Process Control Plan (PCP), Audit, Feedback, and Follow-up Loop)

Step One: Planning

The planning phase supports the definition of required manufacturing and assembly operations associated with the new or modified product content (systems, subsystems, and components) that requires analysis. Participants will receive example criteria and modifiable templates they can use to evaluate any process to determine the PFMEA scope and cross-functional team. The following are elements of the Step One:

⦁ Define the “Voice of the Customer” (Requirements)
⦁ Define Operations that require analysis based on new or modified product
⦁ Define Current Issues (e.g., Field, Test, Internal Manufacturing and Assembly Issues, Supplier Issues)
⦁ Define PFMEA Plan (PFD, PFMEA, PCP requirements)
⦁ Define and Train the Team

Step Two: Preparation

The preparation phase makes the process visible by completing a detailed PFD that includes definition of Product and Process Characteristics associated with each operation step. The training provides modifiable templates and examples that they can use to ensure internal and external stakeholders have a road map to develop a robust process without any hidden factory steps. The following are elements of Step Two:

• Define process layout at required levels (system, subsystem, component)
• Define Current PFD, PFMEA, Control Plans, Work Instructions
• Define the Outputs of each operation (Functions - Product Characteristics)
• Define the Inputs of each operation (Process Characteristics)
• Define known Guidelines and Best Practices for new or modified operations

Note: The engineer and manager (FMEA expert as needed) ensure the correct preparation is complete to engage the cross-functional team in an organized technical review of the manufacturing and assembly processes

Step Three:Technical Risk Analysis (PFMEA)

The assessment phase provides a step-by-step process for the relevant engineer (or team) to complete assessment of their manufacturing and assembly processes. The training material provides modifiable templates and examples organizations can use to complete PFD’s, PFMEA’s, and PCP’s. The following are elements of Step Three:

• Using the PFD to define the PFMEA structure
• Using the PFD to define the function and requirement for each operation in the PFMEA
• Using the PFD to support defining PFMEA Potential Failure Modes
• Using the PFD to support defining PFMEA Potential Causes
• Defining all Failure modes, effects and causes for each operation
• Controls defined for each potential failure mode and potential cause
• On-going proficiency assessment by FMEA Expert

Step Four: Risk Assessment (Calculation and Prioritization)

The engineer (or team) utilizes the PFD to initiate the PFMEA. Technical process reviews will uncover hidden process deficiencies and define process controls that will yield a robust manufacturing and assembly process. The following are elements of Step Four:

• Design and Process Reviews input
• Linkage with DFMEA input to define process risk
• Linkage with DFM/A input to define process risk
• PFMEA Risk Calculation (Ranking)
• Definition of Critical/Special Characteristics
• Define Verification Plan updates to prevent product defects in the customer hands
• Actions Defined to address risk
• Management Review and Approval to Proceed

Step Five: Risk Reduction (Actions and Risk Re-Assessment)

This training connects the output of PFD, PFMEA and PCP methodologies. The processes would have little value if all actions were not completed and there was not verification the manufacturing and assembly processes produced the product to defined requirements. The following are elements of Step Five:

• Actions defined
• Re-assess Risk based on Actions Results
• Supplier Risk Assessment
• Cross-functional Team and Management Review

Step Six: Communicate Risk (Including Process Control Plan (PCP), Audit, Feedback, and Follow-up Loop)

After it has been determined the design will meet requirements, it is recommended the engineer share the learnings with the organization. It is also recommended engineers work with their suppliers to ensure they have completed DFMEA analysis to the same detailed level as defined in this process. If your supplier fails you fail! The following are elements of Step Six:

• Control Plans Developed
• Audit of the PFD, PFMEA and PCP
• Results of Audit reviewed with the organization
• Results of PFD, PFMEA, and PCP reviewed with customers and suppliers
• PFD, PFMEA, and PCP locked for change control and traceability
• 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

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

This PFMEA 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, AS13004 PFMEA and Control Plan Standard, AIAG FMEA Fourth Edition, AIAG-VDA FMEA Handbook, or want to develop a company-specific process to complete PFD’s, PFMEA’s, or PCP’s. PFMEA is a reliability assessment technique recommended and outlined in APQP, PPAP, 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 also 0.9 CEU’s towards their professional certification.