Ultimate FMEA Training : From Beginner To Advanced

Explore failure mode effect analysis (FMEA) as a cross-functional engineering method to identify hazards in product designs and manufacturing, enabling corrective actions and early design changes to reduce risk.

Use FMEA to drive early hazard identification and risk reduction across product design and manufacturing, keeping risks at an acceptable level through ongoing updates.

Explore the primary objective of FMEA: improve design across product, process, and system, while identifying hazards, refining designs, processes, and controls with risk assessment.

Explore system fmea as a high-level analysis of a complete system with subsystems, hazards, severity, and corrective actions, using a car example and contrasting design and process fmea.

Explore design FMEA (DFMEA) at component level, distinguishing from system FMEA, by evaluating how subcomponents like spark plugs and gas tanks affect safety and reliability when designed to specifications.

Explore process fmea, analyzing manufacturing and assembly hazards to improve the process, ensure design requirements are met, reduce downtime, scrap, and rework from raw material to shipping.

Learn to build an fmea from scratch using a generic worksheet, assess severity, occurrence, and detection, compute the RPN, and implement design controls and corrective actions to reduce risk.

Identify the item in fmea as a serial number that names each line, subsystem, or component, using the all-terrain bicycle example to distinguish system fmea from design fmea.

Identify the function as the second column of the FMEA worksheet, describing the item’s intended work in verb-noun format to meet performance requirements, guiding potential failure mode analysis.

Define failure modes within the fmea framework by describing how a brake system may fail to meet its function, exploring rain or worn tires to assess consequences and mitigation.

Explore the potential effects of failure modes on the system and end user in fmea, considering manufacturing impacts and the one-to-many effects, illustrated by brake failure and potential crashes.

Define severity as the objective ranking of the most serious effect using a predefined scale and a 1-to-1 relationship, then build a severity chart from no effect to vehicle operable.

Identify potential causes of failure using root cause analysis in FMEA, exploring design and process deficiencies with examples such as cable binding, external material reducing friction, and brake cables.

Define occurrence in FMEA, explain how to measure its likelihood from design testing and field complaints, and map it to a 1-10 risk ranking.

Explore FMEA controls, including prevention and detection methods, design controls, inline and durability testing, NC 799 and ANSI standards, and risk prioritization number (RPN) calculations to reduce risk.

This lecture explains detection as a ranking for best controls, how it relates to severity and occurrence, and how RPM guides prioritizing high-risk issues.

Learn how risk priority numbers in FMEA combine severity and occurrence (and sometimes detection) to rank failure modes, prioritize high risks, and simplify RPN with severity-occurrence only.

Apply FMEA to reduce high rpm risk with recommended actions, considering controls, cost, and effectiveness, then implement actions and monitor revised severity, occurrence, and detection.

Apply FMEA as a lifelong, company-wide process by establishing a skilled facilitation team, clear scope, and regular updates to anticipate hazards and drive safe, reliable products.