Introduction to FMEA

• Product and process risk assessments & link to Zero Defects
• Challenges of producing Process FMEAs to AS13004 standard

The FMEA Method

Introduction to the FMEA methodology, and link to Design FMEA

• Identify:
  • Failure mode: failure definition

• Assess:
  • Effects & severity: what would be the result of the failure mode and how bad would it be
  • Causes & occurrence: what mistakes could lead to the failure and what are their likelihoods
  • Control & detection: how could failure be detected
  • Current risk: things that need improvement

• Control:
  • Action plan: ideas for improvement
  • Future risk: the impact of the improvements

Process FMEA – Preparation and Identify Phase

• Process boundary setting: what is the subject process
• Process mapping: describing the process
• Design & process linking: Characteristic matrix
• Failure mode identification & specification
• Giving the failure mode some status
• Potential mistake identification and review
• Current process control & its effectiveness
• Evaluating current risk

Process FMEA – Control Phase

• Generation and review of recommended actions
• Action escalation and management
• Outstanding risk after action

FMEA Facilitation (the 5 Ps)

• The use of FMEA reference content
• Preparation – pre-work and ownership
• People – the FMEA team
• Post-event – follow up actions & support