RS 470 Training Seminar
Failure Modes, Effects and Criticality Analysis

The RS 470 training seminar provides an overview of the concepts and procedures for FMEA, FMECA and related analyses, with an emphasis on the use of ReliaSoft's Xfmea software for analysis, data management and reporting.

The training course presents concepts and software tools that you could use to help your organization:

• Proactively consider potential failures, prioritize issues based on risk and then initiate improvements early in development when modifications tend to have the biggest impact for the lowest cost.
• Create a searchable knowledge base of reliability-related information for your designs, which can contribute to the development of test plans, control plans, future design efforts and other activities.
• Comply with supplier or regulatory requirements while promoting analysis and data management processes that are efficient and effective, utilizing lessons learned from past analyses when applicable.

Course Objectives

The objectives for this training course are to:

• Provide attendees with a comprehensive introduction to FMEA/FMECA techniques (from preparing for the analysis through risk assessment and corrective actions).
• Examine the key factors that contribute to successful FMEA projects.
• Provide hands-on training in the use of ReliaSoft's Xfmea software.

Although this course will provide many opportunities for attendees to discuss their particular analysis challenges and to practice the skills required for effective analysis, this course is not intended to provide an in-depth FMEA facilitation for any particular component or product.

Detailed Course Outline

Day 1 Morning

The morning session of Day 1 provides an introduction to and overview of the fundamentals of Failure Mode and Effects Analysis (FMEA) and Failure Mode, Effects and Criticality Analysis (FMECA), including a thorough instruction in the proper identification of failure modes, effects, causes, controls, risk assessment and corrective actions. Topics include:

Introduction and Overview

• Definition and historical background.
• Examine applications and benefits.
• Review types of FMEA/FMECA and published standards:
  • Design FMEA (DFMEA), Process FMEA (PFMEA), Machinery FMEA (MFMEA), System FMEA, Service FMEA, etc.
  • J1739, AIAG FMEA-3, MIL-STD-1629A, etc.

Basic Analysis Process

• How to assemble the team and establish Ground Rules for the analysis.
• How to gather and evaluate Data Sources.
• How to identify and evaluate Items.
• How to identify and evaluate Functions.
• How to identify and evaluate Failure Modes.
• How to identify and evaluate Effects.
• How to identify and evaluate Causes.
• How to identify and evaluate Controls.
• How to identify and evaluate Risk.
• How to identify and evaluate Recommended Actions.
• How to generate Charts and Reports to visualize and publicize the analysis.
• Make Revisions and integrate FMEA/FMECA into decision-making.

Risk Assessment Methodologies

• Risk Priority Number (RPN) rating system for risk assessment:
  • Severity, Occurrence and Detection rating scales.
  • RPN calculations, charts and graphs.
• Other Risk Assessment Methodologies
  • Assessment using Occurrence/Severity Matrix
  • Rating Scale Comparison
  • Severity X Occurrence Metric
  • Risk Ranking Tables
  • Combination Triggers
• Criticality Analysis methodology for risk assessment:
  • Quantitative and Qualitative Analyses.
  • Criticality Reports and Matrices.

Integration with Other Quality Analyses (APQP)

• Design FMEA input to Process FMEA.
• Design FMEA input to Design Verification Plan and Report (DVP&R).
• Process FMEA input to Process Control Plan.
• Process Flow Diagrams.
• Using FMEA to guide development of Maintenance Plans.

Day 1 Afternoon

The afternoon session of Day 1 emphasizes the practical aspects of FMEA/FMECA, including the key elements of successful FMEAs and pitfalls to avoid. Topics include:

Key Factors for Effective FMEA Projects

• How to define the scope, assumptions and limitations that bring about a focused and successful FMEA project.
• Common errors and failures in FMEA practice.
• What should be the size and make up of he FMEA core team, and what backup support is needed?
• What are characteristics of successful FMEA facilitation?
• How to maximize the value of team meeting time
• What pre-work is needed before first meeting.
• How to determine the columns in FMEA worksheet for maximum effectiveness.
• What are FMEA Quality Objectives and how are they used to ensure highest quality result?
• What management reports, reviews and support are necessary to effective FMEAs?
• What are the seven pitfalls to effective FMEAs and how can they be avoided?
• What other tips make for successful FMEA outcomes?

Design FMEA Exercise

• Attendees will form an FMEA team and carry out the fundamental steps of a Design FMEA, learning to avoid the pitfalls.

Process FMEA Exercise

• Attendees will form an FMEA team and carry out the fundamental steps of a Process FMEA, learning to avoid the pitfalls.

Day 2 Morning

The morning session of Day 2 introduces Xfmea and covers many of the features of this versatile software, from setting up the database to generating FMEAs and reports. Topics include:

FMEA Data Management

• Organizing information in databases and projects.
  • Working with databases with and without Login Security.
• Working with Profiles and Libraries to customize the interface and the analysis:
  • Enable/disable and/or rename data fields.
  • Determine rating scales and criteria.
  • Set classifications, categories, priorities and other menu options.
  • Create phrase libraries to save time and ensure consistency.
• Data entry shortcuts, including copy/paste, import/export, phrase libraries, etc.
• Understanding the Hierarchical, Worksheet and Filtered views.
• Defining properties of Analysis, Items, Functions, Failures, Effects, Causes, Current Controls and Recommended Actions.
  • Using shortcuts and tips for data entry, such as import/export, copy/paste, phrase libraries, etc.
• Working with Links and Attachments.
• Working with RPNs and/or Criticality Analysis.
• Managing Recommended Actions.
• Generating and evaluating charts and reports.
• Database administration:
  • Authorized database users.
  • Database backups.
  • Baselines and revision tracking.
• Configuring the workspace (User Setup).

Day 2 Afternoon

The afternoon session of Day 2 is a hands-on workshop, tailored to individual applications.

Hands-on Workshop

• Work through a detailed training guide with step-by-step instructions to complete sample analyses that demonstrate the capabilities of the Xfmea software.
• Discuss implementation options for your particular analysis procedures and reporting requirements.