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Introduction to Failure Mode & Effect Analysis (FMEA)
One day workshop designed with extensive hands exercise to ensure experiential learning for participants
It is not a desirable situation, when an error prone process or defective product, be it in manufacturing or service scenario, which might lead to sudden or gradual failure, and hence increased cost of production, or reduced revenue due to customer rejection thus negatively affecting overall profit of a company. This may also lead to other negative impacts such as customer dissatisfaction, product liability risk, loss of future revenue, damaged customer relationship and dissatisfied employee morale.
Failure Mode & Effect Analysis (FMEA) is a systematic methodology that (1) helps anticipate & early identification of defect & failure mode in design, product or process, (2) help understand & quantify risk associated with defects & failure (3) Plan for risk mitigation with specific actions & responsibilities.
Effective FMEA helps designing out the failures & risk associated with product & process in early stages thus reducing or eliminates errors, in design or process or product. This ensures a company proactively reduce the cost of process or design via reduced errors in process, cost of product or service via reduced defects, improve customer delivery & customer satisfaction and thus help improve company profit overall and employee satisfaction.
FMEA methodology can be applied to products and produces be it in manufacturing or be it in service sectors as part of risk management tool.
It is not a desirable situation, when an error prone process or defective product, be it in manufacturing or service scenario, which might lead to sudden or gradual failure, and hence increased cost of production, or reduced revenue due to customer rejection thus negatively affecting overall profit of a company. This may also lead to other negative impacts such as customer dissatisfaction, product liability risk, loss of future revenue, damaged customer relationship and dissatisfied employee morale.
Failure Mode & Effect Analysis (FMEA) is a systematic methodology that (1) helps anticipate & early identification of defect & failure mode in design, product or process, (2) help understand & quantify risk associated with defects & failure (3) Plan for risk mitigation with specific actions & responsibilities.
Effective FMEA helps designing out the failures & risk associated with product & process in early stages thus reducing or eliminates errors, in design or process or product. This ensures a company proactively reduce the cost of process or design via reduced errors in process, cost of product or service via reduced defects, improve customer delivery & customer satisfaction and thus help improve company profit overall and employee satisfaction.
FMEA methodology can be applied to products and produces be it in manufacturing or be it in service sectors as part of risk management tool.
Objective
- Understanding & constructing effective FMEA documents for various scenarios
- Understanding, comparing & contrasting Design FMEA & Process FMEA
- Various terminology & concepts used in FMEA methodology
- Techniques for Identifying Vital few failures (from many failure modes) for prioritization of Risk Mitigation plans
- Risk Ranking for various situation & industry
- Dos & Donts, Tips & Techniques while developing & implementing an effective FMEA
Outline
- Introduction to FMEA, its uses & benefits
- Strategies & Steps for planning, conducting & documenting FMEA
- Systematic identification of defects, errors & failure modes
- Understanding & quantifying the risk associated with identified problems
- Prioritising the failure modes & risks & their mitigation plans
- Implementing the risk mitigation plans & verifying the effectiveness - Potential roadblocks, challenges while conducting FMEA & overcoming them
- Various case studies
Who should attend
- Product Design & Development Engineers, New Product Introduction (NPI) engineers
- Process Engineers responsible for Development, Implementation & control of process
- Quality Engineers responsible for product quality, process quality, customer quality
- Service Design Engineers, Personnel involved in Service Excellence
- Managers, Senior Managers, General managers involved in manufacturing or service operation and interested in understanding failure mode, risk mitigation plans and customer satisfaction
- Anyone who wants to learn how to identify failure mode early (for products, services, process) and learn how to quantify risk and plan for mitigation
Profile of Ramesh Rao
Ramesh Rao holds bachelor’s degree in Engineering, MBA in finance & supply chain. He also holds Diploma in Adult Continuous Education (DACE) & Advance Certification in Learning & Performance (ACLP) from SUSS Singapore. Additionally, Ramesh comes with multiple professional certifications in Lean Six Sigma Master Black Belt, Design Thinking Facilitation, Agile & project management, Digital Transformation, Industry 4.0, Programming, RPA and more.
Ramesh has over 30 years of career experience both in corporate role as well as in training and consulting. Ramesh has served in leadership role in process & operations management, product & service design, Industrial automation, operational excellence, and as global finance controller for US MNCs serving in multiple countries and continents. As a consultant and trainer, Ramesh has conducted more 2000 training and workshops both public as well as in-house on multiple domains such as Lean Six Sigma, Design Thinking, Agile, Digital Transformation, Financial skills, change management, Data analytics, Statistics, Smart factory solutions etc. Ramesh has served industries such as Manufacturing, Retail, Supply Chain, Banking, Financial Services, Education industry, government sectors, R&D & NGOs across Asia, Europe & USA.
As a DACE & ACLP certification holder, Ramesh has provided WSQ / SSG accredited training for several training providers in Singapore.
