DFMEA Training | Design FMEA Training

What is DFMEA?

DFMEA, or Design Failure Mode and Effects Analysis, is typically used in the early stage of the product lifecycle and development as a troubleshooting and assurance process and tool.

What is FMEA?

Failure Mode and Effects Analysis (FMEA) is defined as a regular technique used to inhibit failure. Such action is conducted through the exploration of potential failure modes and the reasons can cause such failure. FMEA actions occur within a team activity by tackling high severity, high occurrence, and high detection rankings that is determined by the analysis. Only through the preventive process of FMEA we can assure the product performance is satisfactory and the chance of the product failure is reduced. The Design FMEA training course will help you explore these steps in detail and learn how to put them in action to prevent the system failure.

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FMEA techniques are considered as a quality improvement tool. One of the reasons why FMEA has gained interests in recent years is because of automotive industry and implementing ISO/TS 16949. However, other industries such as aerospace, pharmaceutical, and electronics can benefit from such practice as a risk analysis tool and to increase the quality of their products. One of the beauties of this technique is its simplicity. Quality improvement tools are often made of complicated statistical analysis. Such simple yet sufficient and effective quality technique can save costs for the organization.

Learn about:

• What Design Failure Mode and Effects Analysis (DFMEA) is
• How Design Failure Mode and Effects Analysis (DFMEA) is related to Failure Mode and Effects Analysis (FMEA) and Process Failure Mode and Effects Analysis (PFMEA)
• Benefits of Design FMEA
• How to uncover opportunities to prevent failure proactively prior to the failures
• How to collect data and information as part of DFMEA Pre-Work
• How to use DFMEA to investigate and treat risk as actual failure including high severity Failure Modes
• Design Failure Mode and Effects Analysis (DFMEA) process and tools
• Learn about Design FMEA input and output including RPN, severity, occurrence, and detection rankings
• Learn about Requirements, Potential Failure Modes, Effects of Failure and Severity Ranking, Causes, Prevention Controls, Occurrence and Class Column, Detection Controls, calculating the Risk Priority Number (RPN) and more
• Select an Effective DFMEA Cross Functional Teams (CFTs) in your organization
• Analyze your process and plan Cross Functional Teams (CFTs) activities and control
• Plan Design Verification Plan & Report (DVP&R)
• Map design reviews to FMEA Outputs
• Use problem solving activities such as 8D to DFMEA input and output
• Use Design of Experiments (DOE) in conjunction with DFMEA
• Use other tools such as Why-Why, Fishbone Diagrams, Fault Tree Analysis (FTA), 8D, DOE to enhance your Design FMEA activities

Learn how to map Design FMEA Detection to the input into the Design Verification Plan & Report (DVP&R)

TONEX DFMEA Training Methodology

Design FMEA training includes many in-class activities including hands on exercises, case studies and workshops. During the Design FMEA workshops, students bring in their own design work and issues and through our coaching, develop their own Design FMEA.

The DFMEA training course will also address the relationship between FMEA process and FTA, DVP&R, and control plans. This course not only is conducted via lecture but also involves trainees in in-class activities. Students will experience designing and developing a mocking FMEA and risk analysis in the class.

Audience

The DFMEA training is a 2-day course designed for:

• Engineers, scientists, and managers involved with manufacturing
• Production and manufacturing team
• Product design personnel
• Reliability, testing, and quality team members
• R&D personnel
• Product and process assurance people
• Assembly personnel

Objectives

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

• Explain the concept and the purpose of Failure Mode and Effects Analysis (FMEA)
• Discuss the benefits, requirements, and goals of FMEA
• Decide when to use Design FMEA and when Process-FMEA
• Discuss the steps and process of the FMEA
• Gather up an FMEA team
• Define the Design FMEA scope
• Conduct all the steps of Design FMEA
• Conduct the ranking scales for Severity, Occurrence, and Detection
• Choose the appropriate technology methods to use as supplement to their DFMEA action plan
• Make the Design FMEA into an active document
• Develop a Control plan based on Design FMEA
• Determine corrective actions in order to develop a more correct FMEA

Outline

Overview of FMEA and DFMEA/Design FMEA

• Introduction to Failure Mode and Effects Analysis (FMEA)
• Definition of FMEA
• How FMEA works
• Why and where using FMEA
• System/Subsystem/component Design FMEA
• Manufacturing and Assembly Process FMEA
• Machinery and Equipment FMEA (Logistics Support)

Purpose of an FMEA

• Identifying potential risks
• Prioritizing the risks
• Developing an action plan to reduce the risks

Design-FMEA vs. Process-FMEA

• What is DFMEA?
• What is PFMEA?
• Difference between DFMEA and PFMEA?
• When to use which?
• Special features (critical and significant)
• Cooperation on special features
• Characteristics as inputs to PFMEA

Principles of DFMEA/Design-FMEA 

• What Is A Design FMEA?
• Identifying potential or known failure modes
• Corrective and preventive actions
• Disciplined analysis of the product/system design
• Design-based failure modes
• Design FMEA steps and flow
• Examples
• DFMEA Development Methodology
•  Scope
• Clarify your scope
• How to use the DFMEA Scope Worksheet
•  Procedure
• Step-by-step directions of a Design FMEA
• How to use the FMEA Analysis Worksheet
• How to customize the Severity, Occurrence, and Detection Ranking Scales
• Failure Mode Avoidance FMA /FPA Failure Prevention Analysis
• Team structure and rules for efficiency – cross functional teams
• Control Plan
• Some tips on DFMEA

Design FMEA Relations to Process-FMEA

• Scope
  • Clarify your scope
  • How to use the PFMEA Scope Worksheet
• Procedure
  • Step-by-step directions of a PFMEA
  • How to use the FMEA Analysis Worksheet
  • How to customize the Severity, Occurrence, and Detection Ranking Scales
• Control Plan
• Some tips on PFMEA

Design FMEA Training Hands-on and In-Class Activities

• 3 Labs
• 2 Workshops
• 1 Group Activity

Sample  Design FMEA Activity Workshop

• How to complete the Design FMEA Template (TONEX’s DFMEA Template)
• Tools to extract product functions
• Disusing and analyzing potential Failure Modes
• Brainstorming and identifying potential Failure Effects
• Disusing and determining the Severity of the Effect
• Analyzing and identifying Potential Cause(s) of the Failure Mode
• Determining the Probability of Occurrence of the Failure Mode
• Identifying Design Verifications techniques for the Causes
• Determining the Probability of Non-Detection of the Failure Mode
• Prioritizing risks based on Risk Priority Number (RPN)
• Corrective and Preventive Actions
• Techniques to prioritizing Actions Based on the RPN