Training objectives
· Gain the ability to successfully perform a Process Failure Mode and Effects Analysis (PFMEA) according to the AIAG 4th Edition 2008 / SAE J1739:2009 guidelines;
· Gain knowledge of the basic principles of organization of a PFMEA process;
· Learning about the planning and process improvement strategies based on indicators other than RPN;
· Generate a positive attitude towards the method and a belief that it is highly effective and efficient within the team.
Estimated contribution of the practical part: 75%
Duration: 2 days for 8 h
Programme and exercises:
1. FMEA objectives. FMEA as a method of continuous quality improvement and as a method of risk analysing or management.
2. Organization of a FMEA analysis, resources required, role and team composition.
3. The “part-family / generic PFMEA” concept, linking to the PDCA cycle.
4. FMEA for structure (DFMEA) and process (PFMEA) - differences and relationships.
5. Preparation of input data for the PFMEA (product and process requirements/specifications, process flow chart, characteristics matrix, non-conformity records).
6. Formulation of functions, requirements, defects, causes and effects of defects, identification of control measures in the production process; distinction between detection and prevention.
7. Identification and description of special properties (characteristics) in the PFMEA.
8. Supporting tools in the PFMEA: characteristics matrix, flow chart, Pareto analysis, Ishikawa diagram, nWhy.
9. Selection of risk indicators: S (Severity), O (Occurrence), D (Detection) according to the AIAG 4th Edition 2008 / SAE J1739:2009 guidelines. Critical interpretation of the RPN (Risk Priority Number).
10. Design of improvement actions - decision-making based on other considerations than the RPN - new indicators (SOD, SD), hazard rankings, risk matrices.
11. Versions of improvement actions - defect-addressed vs. cause-addressed actions, preventive vs. detective actions.
12. Versions of PFMEA forms.
Exercises:
1. Criteria for decision-making on production process improvement - a case study.
2. Performing a PFMEA for a selected product/process - working in teams:
- process identification: flow chart, functions, quality requirements;
- assessment of the current state of risk for the selected operation/defect (identification of potential defects, consequences, causes, measures such as detection and prevention, risk indicator assessment);
- designing preventive actions, evaluating their hypothetical effectiveness;
- discussion of the results.
A pre-test/post-test (only at the Customer’s request for closed training courses; training time: + 0.5 h/day).
