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Failure Mode & Effect Analysis (PFMEA)

Reverse PFMEA WORKSHOP – shopfloor oriented

Overview

  • Duration: 2 days
  • Participants: <10
  • Languages: EN, ES, DE, FR
  • Mode: on-site (PFMEA Workshop)
  • Pedagogy: real-experience examples & exercises
  • Evalutation: based on interaction & final evaluation

Target group

  • Participants:
    Engineers, Middle Managers, Supervisors
  • Prerequisite:
    None

Objectives

  • PFMEA filled out as a risk management tool instead of simple documentation
  • Clear potential causes properly identified and linked with potential failure modes
  • Critical and significant characteristics properly cascaded from customer design to the manufacturing process
  • Proper evaluation of severity, occurrence, criticality and risk prioritization.
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    Initial Situation

  • Unexpected product defects and rejects that were not identified in the process design verification step
  • Process controls seem to be useless because product defects are reaching final inspection and customer
  • Processes allow operators to make mistakes that affects quality and process controls are not effective in detection
  • Unexpected process failures due to risks that were not identified in the process design verification step.
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    Introduced Tools

  • Flow diagram, function analysis
  • Characteristics matrix
  • Risk Limiting Method
  • Prioritization matrix, LOP tracker
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    Content

  • Introduction. FMEA definition, types of FMEA. APQP cycle, milestones
  • Inputs, roadmap and outputs. AIAG-VDA FMEA, proposed form, input data and deliverables, FMEA roadmap
  • FMEA team. Teamwork, team composition, team leader roles, roles and responsibilities
  • Input data. Project scope, process description, flowcharts, step-by-step, process functions
  • Risk analysis. Failure modes, effects, Severity values, root causes, Occurrence value, current controls, prevention and detection, Detection
  • Risk management. Prioritizing actions, preventive actions, detection, controls definition
  • Control plan definition
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