FMECA Training | Failure Mode, Effects and Criticality Analysis Training

FMECA Training | Failure Mode, Effects and Criticality Analysis Training

The FMECA Training, Failure Mode Effects and Criticality Analysis Training course covers the theory, principals, techniques, and best practices of FMECA.

Values of FMECA Training

FMECA is a crucial methodology to root cause analysis and reliability assessment. The whole manufacturing process, from designing to maintenance, can benefit from this method. FMCEA is used to identify all the potential failure modes in the system, or sub-systems within the system, how severe they can be, how frequently they might happen, and what would be their impact on the system. Critically analysis adds an extra assessment to evaluate how serious these failure modes are going to be.

FMECA can be used on early stages of designing a product/process or to an existing process/product. In order for an FMECA to function effectively, it needs to be developed based on the nature of the design process itself. FMECA also requires considering operating and service issues, whereas it includes process and safety issues at the same time.

When FMECA is applied matters. Such timeline determines if a FMECA is effective or not. An effective FMECA is the one applied on early stages to prevent all kinds of failure modes.

FMECA Fundamental Elements:

In this FMECA training course, we will discuss and cover the basic information you would need in order to develop an effective FMECA. These elements include:

• Item(s)
• Function(s)
• Failure(s)
• Effect(s) of Failure
• Cause(s) of Failure
• Current Control(s)
• Recommended Action(s)
• Plus other relevant details

You Will Also Learn About:

• Operating document
• Identifying and recording all the potential failure modes
• Analyzing the impact of each mode
• Determining the frequency of the modes
• Analyzing the seriousness of the effects
• Root cause analysis
• Incorporating the already known modes recorded in database
• Developing corrective actions
• Evaluating the impact of the changes stress levels

Why TONEX?

TONEX with a record of offering and delivering high quality training for more than 15 years and having the experience of consulting prestigious private and governmental clients is the best choice for you to receive FMECA training. Our instructors work hard to make sure you finish the training with sufficient knowledge and skills required to develop and execute an FMECA relevant to the nature of the product or process you are involved in.

In addition, TONEX FMECA training includes many in-class activities including hands on exercises, case studies and workshops. During the FMECA workshops, students bring in their own design work and issues and through our coaching, develop their own FMECA Failure Mode and Effects Criticality Analysis (FMECA).

Audience

The TONEX FMECA Training, Failure Mode Effects and Criticality Analysis Training is a 2-day course designed for:

• Cross functional team members
• Internal auditors
• Quality team members
• New product development managers
• R&D personnel
• All individuals who are involved in the process of prioritizing reliability improvement and/or determining the potential failure modes and suitable inhibitory actions.

Training Objectives

Upon the completion of this workshop, the attendees are able to:

• Understand and perform the principals of FMECA
• Understand criticality analysis techniques and their use in prioritizing equipment and reliability improvement work.
• Play an active role in equipment criticality analysis
• Select proper criteria to apply FMECA
• Apply FMECA in developing equipment maintenance strategies
• Use the FMCEA policies in real-life examples
• Identify all the potential significant and crucial failure modes on early stages
• Eliminate potential failure modes through effective corrective plans
• Decide whether to use an FTA or a FMECA

Course Outline

Overview

• FMEA and FMECA definition
• Terminology
• Background and history
• Needs for FMECA
• Applications and benefits
• Other methods competing with FMECA
• Pros and Cons of FMECA against other methods

Introduction to FMECA

• Elements and components of FMECA
• Reliability tools and techniques
  • Methods for fault avoidance
  • Methods for architectural analysis and assessment
• Top down or Bottom up?
• Bottom-up method
  • Event tree analysis (ETA)
  • FMECA
  • Hazard and operability study (HAZOP)
• Top-down method
  • Fault tree analysis (FTA)
  • Reliability block diagram (RBD) – Markova analysis
• Scope definition and worksheet functions
• Functional analysis
• CMMS systems

FMCEA Techniques

• Hardware approach
  • Analyzing the failure modes of each individual hardware
  • When items can be analyzed separately
  • It’s a bottom-up method
• Functional approach
  • Identify and analyze each item based on their functionality
  • When items cannot be analyzed separately
  • It’s used when the process is designed and functional block diagrams are developed
• What is a functional block diagram?

Failure Modes

• Failure definition
• Failure modes classification
  • Complete failure
  • Partial failure
  • Intermittent failure,
  • Function out of specification
  • Unintended function
• Potential failure modes
• Potential causes of failure
• The effects of the causes
• Failure mode ID
• Assembly, sub-assembly, parts
• Failure description
• Alarming signs
• Techniques of failure detection
• All potential effects on assembly and on complete product
• Failure modes exercise

Criticality Analysis

• How does it work?
• How to choose the most proper and suitable criteria
• Categories of severity
• Occurrence classification
• Frequency assessment
• Detection rating
• Calculating criticality
• Qualitative approach
• Quantitative approach
• Applications of the criticality analysis results
• Definition of the “priorities”
• Risk Priority Number (RPN)

FMECA Checklist

• Description and specification
• Ground rules
• Block diagram
• Failure modes identification
• Failure effective assessment
• RPN ranking
• Corrective actions
• Report and documentation 

Gathering Up The FMECA Team

• Design engineer
• Manufacturing engineer
• Customer service representative
• Testing operations representative
• Suppliers representative
• Corporate quality engineer/manager

Putting Together

• Get a spreadsheet program
• Get enough room
• Do the headings first
• Choose appropriate words
• Record decisions and actions in columns
• Associate a ref. number to each failure mode
• Learn the guidelines and standards relevant to you, e.g. MIL-STD 1629 and BS5760 Part1
• Use reliability block diagrams for your analysis
• Set up a completion date
• Practical exercises
• Applying the results to create successful maintenance policies
• Target reliability improvement opportunities

TONEX Hands-On Workshop

• Selecting a topic or project
• Brainstorming
• Scoring System Development
  • Severity of Failure
  • Probability of Occurrence
  • Ease of Detection
  • Risk Priority Number
• FMECA Process
  • Describing the system and its operating requirements
  • Developing functional and reliability block diagrams
  • Developing mathematical models
  • Establishing of basic principles
  • Determining failure modes, their causes and effects, their relative importance, and their sequence
  • Determining failure detection and isolation provisions
  • Determining design and operating provisions against particularly undesirable events;
  • Criticality analysis
  • Evaluating failure probability
  • Look for combinations of multiple failures
• Mitigation of Failures
• Criticality Analysis

FMECA Training | Failure Mode, Effects and Criticality Analysis Training