PFMEA
PFMEA & Control Plan
Objectives and intended outcomes: Upon successful completion of the course participants will be able to:
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Determine if an FMEA needs to be done and to state the specific objectives of each FMEA
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View a process and create a process map quickly
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Quickly list the process outputs
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List the input variables that could create variation in the outputs of the process
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Quickly identify any preventative or detective controls already in place
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Quickly evaluate if any important variables are missing
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Quickly fill in the FMEA and ready it for discussion before the team is ever assembled
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Create an FMEA agenda and assemble the team members relevant to the agenda
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Define and prioritize risk
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Engage the team in proactively solving risk priorities
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Follow up on risk mitigation activities
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Develop a control plan and directly link it to the risks requiring control found in the PFMEA
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Report out to leadership on the findings and value of each FMEA
Intended Audience: This course is designed for all manufacturing, quality and continuous improvement professionals who lead teams in designing and understanding manufacturing and transactional processes.
Prerequisites: This workshop focuses on the skills development and assumes those attending possess experience and understanding of manufacturing or transactional processes, and have participated in continuous improvement teamwork. In lieu of direct experience, it is strongly recommended that learners have a degree in a higher education and some leadership skills in team dynamics.
Instructor: The class is taught by a FMEA subject matter expert with over 20 years of experience. The instructor is engaging and passionate about FMEAs and has traveled the world teaching and showing practitioners how to find the value of both Design and Process FMEAs.
DESCRIPTION:
Process Failure modes & Effects Analysis & Control Plan: This class is a two day practitioner’s course. You will learn so much in this jam packed course you will feel like you’re the expert and extremely well prepared to find the value in your next PFMEA. If taken as part of one of our 10 day training packages it entitles you to 1 hour of free consulting*. Taking this course is the first step in qualifying the practitioner to be certified** as a PFMEA Practitioner.
What is FMEA? Failure Modes and Effects Analysis is a systematic approach to the analysis of complex products and processes. It helps teams evaluate the risks associated with the various requirements of the product or process being evaluated. This PFMEA course is designed to help the practitioner understand the best practices used to properly complete the process FMEA, avoid the common problems teams encounter, and find the true value of completing the FMEA. This class takes away the guess work and “brainstorming” taught in so many classes, and replaces it with a methodical, mechanical approach that gets the team consistent results quickly.
When do we do the PFMEA? The FMEA is a proactive process. It is intended to identify, document and take action to limit or stop potential failure modes before they occur. This risk identification process drives the process creation team to know their process well, before it is physically created. Therefore it is important the FMEAs are started as early as possible. If the FMEAs are created late, the window of opportunity to complete the necessary risk mitigating actions become more constricted, and the cost of implementing those risk mitigating actions becomes more expensive.
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This said, it is most often the case a PFMEA is completed well after the process has been implemented. It is often required later because the products produced by the process are seeing high failure rates due to processing issues, or there is a quality management system demanding process documentation that proves the PFMEA has been completed. Of course neither of these scenarios should be the driver of when or why a PFMEA should be done. However when these reasons are the catalyst that drives management to require the PFMEA be completed, it is critical the team performing the PFMEA recognizes that when a process is created all of the potential failure modes are created as well. The failure modes exist in the process whether we recognize them or not. They are there in the process just waiting for the right circumstances to trigger the failure. The purpose of the PFMEA is to acknowledge these failure modes exist, that there is risk associated with them, and to take action to mitigate the identified risk.
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