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FMEA Training

TONEX FMEA Training, for complete course outline CLICK HERE

TONEX FMEA Design, FMEA Process FMEA and FMEA Services
Learn the impact and importance of Failure Mode and Effects Analysis (FMEA) applied to product and process design. TONEX effective FMEA Training serves as the best FMEA Training solution for your organization: the best practices, best methods combined with the hands-on problem solving skills through the workshop. Improve Quality and Productivity:

  • Standard FMEA Training
  • Design FMEA (DFMEA) Training
  • Process FMEA (PFMEA) Training
  • Prevention of failure using FMEA
  • Acquisition of knowledge of FMEA in design and process
  • Efficient FMEA development using proven methods, tools and process


History of FMEA

FMEA was first used in the 1960’s by NASA in the Aerospace industry during the Apollo missions
In 1974. The Navy developed MIL-STD-1629 to be used along with FMEA
In the late 1970’s, the automotive industry later joined to develop FMEA variations.


Failure Modes and Effects Analysis (FMEA) serves as a valuable tool and method for preventing failure in product and process design.

Learn how FMEA can be planned planned along with product development to mitigate risks and increase the acceptable level of product or process. FMEA is considered as a reliability planning tool and a method for prioritizing alternative actions.

Failure Mode refers to the manner in which the product/part or service does not meet the stakeholder or customer’s expectations. While Effects Analysis is the  study of the effects of failure on the function or purpose of the product/part or service.

FMEA Training course shows you how to recognize and evaluate the potential failure modes and causes associated with the designing and manufacturing of a product.
Learn how to identify actions tha can eliminate or reduce the chance of the potential failure occurring.

DFMEA and PFMEA are the two most common form of FMEA:

  • Design FMEA DFMEA allows you to maximize system quality and reliability and minimize design-based failure effects on the system
    Process FMEA PFMEA  allows you to maximize system quality, reliability, and productivity at the same time minimize production process failure effects on the system
  • PFMEA allows you to minimize variation around the design specification
  • DFMEA and PFMEA are used to discover failures as early in product development
  • Risk is the main substitute for failure in product and process development.

Who Should Attend

  • Design Team
  • Design Engineer
  • Design Leader
  • Test Engineer/Technician
  • Reliability Engineer
  • Quality Engineer
  • Product Marketing
  • Product Manager
  • Material Management
  • Purchasing
  • Field Service Engineer
  • Technician Process
  •  Responsible Manufacturing
  • Process Engineer
  • Process Leader
  • Tooling Engineer and Technician
  • Responsible Operators
  • Maintenance Technician

An FMEA id

entifies the ways in which a product or process can fail. FMEA also estimates  the risk associated with specific causes and it prioritizes the actions that should be taken to reduce risk.

FMEA Procedure Step by Step

For each process input (start with high value inputs), determine the ways in which the input can go wrong (failure mode)

  • For each failure mode, determine effects
  • Select a severity level for each effect
  • Identify potential causes of each failure mode
  • Select an occurrence level for each cause
  • List current controls for each cause
  • Select a detection level for each cause
  • Calculate the Risk Priority Number (RPN)
  • Develop recommended actions, assign responsible persons, and take actions
  • Give priority to high RPNs
  • MUST look at severities rated a 10
  • Assign the predicted severity, occurrence, and detection levels and compare RPNs
  • Severity, Occurrence, and Detection Severity
  • Importance of the effect on customer requirements
  • Occurrence
  • Frequency with which a given cause occurs and
    creates failure modes (obtain from past data if possible)
  • Detection
  • The ability of the current control scheme to detect
    (then prevent) a given cause (may be difficult to estimate early in process operations).
  • Rating Scales
  • There are a wide variety of scoring “anchors”, both quantitative or qualitative
  • Two types of scales are 1-5 or 1-10
  • The 1-5 scale makes it easier for the teams to decide on scores
  • The 1-10 scale may allow for better precision in estimates and a wide variation in scores (most common)
  • Severity
  • 1 = Not Severe, 10 = Very Severe
  • Occurrence
  • 1 = Not Likely, 10 = Very Likely
  • Detection
  • 1 = Easy to Detect, 10 = Not easy to Detect
  • Risk Priority Number (RPN)
  • RPN is the product of the severity, occurrence, and detection scores.

Course Agenda

Introduction to FMEA

  • FMEA Process Overview
  • History and Purpose of FMEA
  • FMEA Applied
    • Manufacturing
    • Design
    • Software
    • System
  • Methodology and process improvement
  • Identification and elimination of concerns early in the development of a process or design
  • Improve internal and external customer satisfaction
  • Focus on prevention
  • FMEA as a structured approach
  • Identifying the ways in which a product or process can fail
  • Estimating risk associated with specific causes
  • Prioritizing the actions that should be taken to reduce risk
  • Evaluating design validation plan (design FMEA)
  • Control plan (process FMEA)
  • Requirements and procedures for performing a failure mode, effects, and criticality analysis (FMECA)
  • Failure mode analysis
  • System safety, system performance, maintainability, and maintenance requirements
  • When to Conduct an FMEA
  • Process improvement investigation
  • When new systems, products, and processes are being designed
  • When existing designs or processes are being changed
  • When carry-over designs are used in new applications
  • After system, product, or process functions are defined, but before specific hardware is selected or released to manufacturing
  • Defining the Risk
  • FMEA in Systems Engineering
  • FMEA as a reliability tool
  • FMEA applied to Systems, Subsystems and Component Design
  • Process FMEA applied to Manufacturing and Assembly
  • FMEA applied to Machinery and Equipment
  • FMEA Applications
  • FMEA Application Case Studies: Aerospace, Medical, Automotive, Machinery, etc.
  • What is a FMEA Development Methodology?
  • Failure Mode Avoidance (FMA)
  • Failure Prevention Analysis (FPA)
  • FMEA Team Structure
  • Design and Process FMEA (DFMEA and PFMEA) Objectives
  • Similarities and Differences between DFMEA and PFMEA
  • Overview of Functions / Failure Modes / Effects of Failure / Severity
  • Severity Ranking
  • High Severity (9 and 10)
  • Causes / Prevention Controls / Occurrence
  • Occurrence Ranking
  • Using Fault Tree Analysis (FTA)
  • Actions to eliminate or reduce cause probability
  • Verification Methods
  • Detection Ranking
  • Risk Priority Number (RPN)

MIL-1629 Standard Applied

  • Criticality analysis (CA)
  • Damage effects
  • Primary damage effects
  • Secondary damage effects
  • Damage mode
  • Damage mode and effects analysis (DMEA)
  • Detection mechanism
  • Environments
  • Failure cause
  • Failure effect
  • Local effect
  • Next higher level effect
  • End effect
  • Failure mode
  • Failure mode and effects analysis
  • FMECA-Maintainability information
  • Indenture level
  • Single failure point
  • FMECA planning
  • Ground rules and assumptions
  • Coordination of effort
  • General procedures
  • Contributing information
  • Technical specifications and development plans
  • Trade-off study reports
  • Design data and drawings
  • Reliability data
  • FMEA process
  • Severity classification
  • Category I and Category II failure mode list
  • Single failure points
  • Detail requirements
  • Failure mode and effects analysis
  • Criticality analysis
  • FMECA-maintainability information
  • Damage mode and effects analysis
  • Failure mode, effects, and critically analysis
  • Example of a functional block diagram
  • Example of a reliability block diagram
  • Example of FMEA worksheet format
  • Example of CA worksheet format
  • Example of criticality matrix

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