Public Training Program : MARCH 23 & 24, 2009 (Concorde Hotel Shah Alam)

Tough Times are the Time for Operational Excellence!

(HRDF CLAIMABLE SBL SCHEME)

Effective Failure Mode Effect Analysis (FMEA) for Process or Product Quality Improvements
FMEAs can transform compliance into competitive advantage

In this challenging economic environment, it is true to the core that good operational excellence and best manufacturing practice are essential to survive and come out a winner to face an economic turnaround! Turn your plant into a training hub to create a niche working culture to embrace the soon to come ECONOMIC BOOM! COME EXPERIENCE OUR TRAININGS AND YOU WILL NOT BE DISAPPOINTED!
ARE YOU WORKING FOR YOUR TOOLS OR ARE YOUR TOOLS WORKING FOR YOU? RUSHING TO COMPLY WITH AUDITOR REQUIREMENTS AND APPEASE CUSTOMERS CONCERNS?

FMEA System Barriers to Success Each barrier can be classified into one or more of three types: subject matter, process or cultural. A subject-matter barrier arises if, for example, a project manager doesn't know how to use the company's project management software tool. A process barrier arises when an organization's purchasing department requires eight bids and six months for approval simply to procure a few bolts. Many organizations that are caught up in a whirlwind of projects are sorely tempted to jump in and start executing the project work without proper planning.
Commercial in Confidence

Course Preview
Customers are placing increased demands on companies for high quality, reliable products. The increasing capabilities and functionality of many products are making it more difficult for manufacturers to maintain the quality and reliability. Traditionally, reliability has been achieved through extensive testing and use of techniques such as probabilistic reliability modeling. These are techniques done in the late stages of development. The challenge is to design in quality and reliability early in the development cycle. Where most quality control technique makes use of some form of statistical application and analysis of data, Failure Modes and Effects Analysis (FMEA) draws upon experience to make quality improvements, therefore being non-threatening and more acceptable. It is an early warning and preventive technique that provides a methodical way of studying the causes and effects of failures before the product or process design is finalised. And it is also an effective way to carry out Contract Review (ISO9000 series) FMEA is methodology for analyzing potential reliability problems early in the development cycle where it is easier to take actions to overcome these issues, thereby enhancing reliability through design. FMEA is used to identify potential failure modes, determine their effect on the operation of the product, and identify actions to mitigate the failures. A crucial step is anticipating what might go wrong with a product. While anticipating every failure mode is not possible, the development team should formulate as extensive a list of potential failure modes as possible. The early and consistent use of FMEAs in the design process allows the engineer to design out failures and produce reliable, safe, and customer pleasing products. FMEAs also capture historical information for use in future product improvement. The use of FMEA in the field of maintenance has systemized the process of designing Preventive, Predictive and Autonomous maintenance. This topic will be discussed as an example to see the application of FMEA.

Course Objective
To learn the methods of applying FMEA to identify and prevent potential failures in the product and process Management and Improvement.

Course Benefits
Participants will develop the ability to: select potentially reliable and safe design alternatives during the early design phases consider conceivable failure modes and their effects on operational success list potential failures and identify the relative magnitude of their effects provide a basis for test programs during development and final design validation develop early criteria for manufacturing processes provide historical documentation for field failure analysis and design/process improvements establish corrective action priorities organise defect prevention efforts

Commercial in Confidence

Course Outline Day 1 UNDERSTANDING FMEA & LEARNING HOW TO USE FMEA EFFECTIVELY
Introduction & Background Framework & Applications Types of FMEAs FMEA Usage Benefits of FMEAs

Break
System Design Product Process Mechanics Methodology Tabular Approach of Manufacturing Industries

Break (lunch)
FMEA Project Planning Organizing the Team & Disciplines Responsibility & Schedules Failure Occurrence Probability : Effect Severity Failure Detection Probability Occurrence Severity Detection Ranking

Break
FMEA Implementation Steps Using The FMEA Worksheet Understanding the Process/Product & Mapping Identifying Failure Modes Identifying & Rank Effects of Each Failure Mode Identifying Causes & Probability Factors of Failures Modes Determine Likelihood of Detection Review Risk Priority Numbers (RPN). Determine Recommended Actions Assign Responsibilities & Actions Monitor & Update FMEA Successes

Commercial in Confidence

Day 2 - Practical Action Learning To Develop FMEA FOR Process or Product Quality
1. 2. 3. 4.

Product FMEA (Action Learning 1)

Product Problem Solving Goals Execution of PFMEA Steps on Shop-floor Presentation of Findings Brainstorming/Fine-tuning

Break
Develop Product FMEA Work Instructions

Break (Lunch)
1. 2. 3. 4.

Process FMEA (Action Learning 2) (Preventive Maintenance Failure Mode Effect Analysis) PMFMEA
Process Problem Solving Goals Execution of PMFMEA Steps on Shop-Floor Presentation of Findings Brainstorming/Fine-tuning

Break
Develop Process FMEA Work Instructions Course Wash-up & Summary Feedback Questionnaires

Commercial in Confidence