FMEA: Failure Modes & Effects Analysis

• Introductory concepts.
  • FMEA and FMECA definitions.
  • FMEA objectives.
  • Process versus product FMEA.
  • Pre-design, design, and post-design effectiveness.
  • Prediction versus detection.
  • The predictive nature of FMEAs.
  • Soliciting and including appropriate expertise.
  • Applicable standards.
  • Tabular analysis organization.
  • Class exercise.
• FMEA Elements.
  • Mechanical component failure modes.
  • Electronic component failure modes.
  • Electrical equipment failure modes.
  • Hydraulic equipment failure modes.
  • Assessing failure effects at component, subassembly, next assembly, and system levels.
  • Criticality definitions and determinations.
• Product FMEA Preparation.
  • Tabular formats.
  • Using Word and Excel when preparing FMEAs and FMECAs.
  • Class FMEA/FMECA preparation exercise.
  • Critical, major, minor, and negligible definitions.
  • Corrective and preventive action.
  • Corrective action order of precedence.

Day 2: Quantification, Report Preparation, and Course Wrap-Up.

• Process FMEAs.
  • Process versus Product FMEAs.
  • Assessing production, operational, quality assessment, and administrative processes.
  • Assessing redundancy defeaters.
  • Tapping outside resources.
  • Developing improvement recommendations.
  • Class exercise.
• FMEA Quantification.
  • Failure rates, MTBF, and probability of failure.
  • Failure rate sources.
  • Human error failure rates.
  • Failure rate versus environment.
  • MIL-HDBK-217F, NPRD-95, and MIL-STD-1629.
  • Dormant versus active failure rates.
  • Assessing storage failure mechanisms.
  • Class exercise.
• The Failure Mode Effects Summary (FMES).
  • FMES purposes.
  • Using Excel’s sorting features to streamline FMES preparation.
  • Quantifying failure mode effects.
• The FMEA Report.
  • System descriptions.
  • Citing data sources.
  • Using the FMEA to streamline reliability predictions.
  • Embedding Excel and *.pdf files to accelerate preparation.
• FMEA Cost Estimation.
  • Related reliability and system safety analyses.
  • Other information sources.
  • Estimating FMEA preparation costs.
• Course Summary, Review, and Critique.
  • Recap, Q/A, and evaluations