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Product Development using SFMEA, DFMEA and Associated Tools

Seminar Content

This two-day, hands-on seminar is intended to offer insight into, and hands-on experience with, the linkages between various aspects of the Advanced Product Quality Planning (APQP) process. Specifically, the development and linkage of Block Diagrams, Interface Matrix, System and Design FMEAs and Design Verification (Test) Plans (DVPs) are addressed.

SFMEAs are performed during the Design phase of APQP for Risk Management and Prevention. SFMEAs are used to identify Special Requirements, Critical Items and Key Characteristics to assist in the flow-down to sub-assemblies and components.

This seminar includes breakout exercise sessions using an example of appropriate complexity so that the participant has the opportunity to grasp both System FMEA and Design FMEA concepts. A key part of this course is applying the concepts during the breakout sessions.

Who Should Attend

This seminar is designed for Program Managers, Project Managers, Design Engineers, Quality Managers, Quality Engineers, APQP Team Members, and all other Risk Management personnel.

Recommended Training and/or Experience

Participants should possess a working knowledge of quality systems and methodologies.

Seminar Materials

Each participant will receive extensive course material.

Seminar Goals

  • Explain the difference between DFMEA and SFMEA
    • Demonstrate an ability to properly construct a Boundary (Block) Diagram
  • Explain how to incorporate single and multipoint FMEAs into the same FMEA (Omnex method)
  • How to build a FMEA that links with FTA and FMEDA (Omnex method)
  • Explain the use of an inter-relationship matrix to identify relationships between components and higher level systems
  • Demonstrate an ability to properly and effectively complete all items in the DFMEA process
    • Identify Functions, Requirements, Failure Modes, Causes and Controls and properly enter the information in a DFMEA
  • Demonstrate how to use the output from a DFMEA to develop a test plan (DVP&R)
  • Explain how a DFMEA can help identify effects and severity for a process failure mode
  • Identify special characteristics in product design
  • Continual improvements with a focus on the use of Sev, Sev x Occ, and Sev x Occ x Det ratings

Seminar Agenda

  • Setting the Stage: APQP Overview
  • Introduction to Failure Mode and Effects Analysis (FMEA)
  • Developing an FMEA
  • Design FMEA Prerequisites
    • Breakout Exercise: Customers and Functional Requirements
    • Breakout Exercise: Boundary Diagram
    • Breakout Exercise: Function Analysis and Requirements Flowdown
  • Developing the Design FMEA
    • Breakout Exercise: Starting the DFMEA Form
    • Breakout Exercise: Failure Modes
    • Breakout Exercise: Design Causes
    • Breakout Exercise: Design Controls
    • Breakout Exercise: Effects and Severity
    • Breakout Exercise: Classification (Key Characteristics)
    • Breakout Exercise: Risk Analysis and Mitigation
    • Breakout Exercise: Implementation (Instructor-led)
    • Breakout Exercise: Thinking Ahead to FTA and FMEDA (instructor-led)
  • Test Planning and Reporting
    • Breakout Exercise: DVP&R
  • Summary

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