Learn the Failure Mode Effects Analysis (FMEA) Core Tool and help improve your 16949 Quality Management System

The Automotive Quality Core Tools are the building blocks of an effective quality management system. They include Advanced Product Quality Planning & Control Plan (APQP), Production Part Approval Process (PPAP), Failure Mode and Effects Analysis (FMEA), Measurement System Analysis (MSA), and Statistical Process Control (SPC).

Failure Mode and Effects Analysis (FMEA) is a logical technique utilised to identify and eliminate possible causes of failure. FMEA technique requires a sequential, disciplined approach to assess systems, products or processes in order to establish the modes of failure and the effects of failure on the system, product or process. This is to ensure that all possible failure modes have been fully identified and ranked in order of their importance.

FMEA techniques have been around for over 40 years. In recent years, use of FMEAs has gained popularity as a quality improvement tool. This interest is in large part due to the automotive industry and specifically its IAFT 16949 supplier requirements. Other major industries, including aerospace, medical products and electronics are also using FMEA techniques as part of their improvement and risk assessment strategies. Unlike many quality improvement tools, FMEAs do not require complicated statistics. FMEA studies can yield significant savings for a company as well as reduce the potential liability of a process or product that does not perform as promised.

The FMEA discipline requires the engineers to document their evaluation with regard to the failure mode, effect and criticality (FMECA). The analysis work can be applied at any stage; design, manufacture, test, installation or use, but it is best performed at the design stage.

In a simple system, FMEA may be performed on the total system or product but with more complex systems it may be necessary to break the product down into various sub-systems or sub-assemblies.

Increasingly, contracts are requiring Failure Mode and Effects Analysis (FMEA) to be performed as a condition of placing the order. Also, the use of FMEA minimises the company’s likely exposure to very expensive product liability claims.

FMEA techniques are applicable to all industry sectors, though companies supplying the automotive industry or seeking compliance and registration to ISO/TS 16949, are required to use FMEA techniques to achieve product assurance.

When properly applied the FMEA process can be used to:

Identify or eliminate the potential causes of failure during the product design process, thus speeding up the development process and reducing the number of late changes

Identify critical characteristics of sub-systems and components in a complex product or process

Develop an effective control plan that will reduce the risk of project or product failure due to late delivery and cost overruns

Improve customer satisfaction and reduce warranty costs

This two day practical FMEA training course introduces the principles behind the FMEA techniques and explains how they can be applied at each stage of product and process development. It will provide delegates with a basic knowledge of the FMEA methodology, how to apply it to product and process design, and demonstrate how the results of the FMEA are used to define the requirements for an effective product validation plan, and an effective control plan for the manufacturing process.

*This course can be tailored to your requirements and delivered ‘in-house’ at your premises or in one of our well equipped training venues.