FMEA (Failure Mode & Effects Analysis) Product & Process Training (in-house / on-site)

Leaving you with:

• FMEA documentation on your products or processes to be used as legal documents and templates for conducting FMEA on new products and processes
   
• Ready functional models of your products or  flowcharts/maps of your processes that can be used for Employee product/process training, Continuous Improvement processes, and Root Causes Analyses

• A Team that embraces the concepts of systems' engineering, systematic risk analysis and continuous improvement
  

Formal Risk Assessment using FMEA is a requirement for product and process design. It is now part of ISO9001 and Advanced Product Quality Planning (APQP).

FMEA is a cross-disciplinary collaborative process. When performed correctly, it utilises the knowledge of all participating members to improve the target product or process and enables knowledge transfer between participants. Completed FMEA documents are “living” documents: They are used to improve your products/processes continuously and constitute evidence of conducting formal risk assessment.

As with any process improvement tool, FMEA’s output quality depends on the quality of the data inserted by the FMEA team (e.g., process steps, potential failure modes, causes and metrics). In detail, FMEA processes require:

1. An FMEA specialist to facilitate the process and ensure a structured assessment of the product or process
    
2. A focused, jargon-free product process map to assist communication between the team members (FMEA members come from different business functions and do not share the same jargon)
    
3. Performance metrics for fault occurrence and detection. For FMEA on novel  components/processes, known metrics from similar components/ processes should be used
    

Training one or two members of your team using generic FMEA training courses leaves them with the great challenge of putting the newly acquired theoretical knowledge into practice and becoming the champions of the process. This challenge is often too big, and the trained candidates fail to implement the theory in their business setting.

Based in London, we offer training for your on-site/in-house team while conducting an FMEA on your product/ process. This approach will engage everyone throughout the process (from identifying failure modes to measuring the effects of proposed improvements) and produce an FMEA document that is relevant and compatible with your business needs.

Our Functional Analysis Diagrams (FAD) assisted FAD-FMEA approach has been repeatedly tested in SMEs (both PFMEA and DFMEA processes) with no previous FMEA experience and published in peer-reviewed scientific journals and conference papers. An overview of the Functional Model assisted FMEA can be seen here. The functional models constructed before the FMEA sessions significantly assist cross-disciplinary collaboration, minimise the risk of missing out on essential failure modes, and reduce the time needed to identify potential failure modes and effects. 

Functional Modelling is now required by the AIAG-VDA FMEA  (2019) process to identify product functions.

 While the exact process will vary depending on your specific needs, the main steps involve:  

• Initial free consultation to discuss your needs
• Our proposal submission with any agreed confidentiality (NDA)
• We develop functional models/ flowcharts in liaison with your product/ process delegate
• All Team members review models
• Multi-disciplinary Team introduction into FMEA theory
• Complete practical FMEA training on your Product/ Process
• Identify actions required & develop an evaluation plan
• Follow-up FMEA session to evaluate product/ process
• Discuss using FMEA documentation throughout the lifetime of your product/ process
• Ongoing Management of process if required

While the cost of our consultation and training can be comparable with the total cost of sending your team on a standard FMEA training course (using ready, generic examples), the difference is that we deliver a completed FMEA and greatly improve the chances of FMEA process adoption. by:

• Bringing the training to you (on-site / in-house) 
• Working with your teams to develop functional models (maps) of YOUR product or process    
• Use the functional models to train your team in identifying and analysing the relationships between customer (internal or external) requirements and product/ process components  
• Facilitate the FMEA process and create FMEA documents for your products/ processes with your team  
• Facilitate a follow-up FMEA processes to assess the reliability of the product/ process after the proposed actions were completed (this can be a remote session)  
• Provide a set of tools, documentation and remote support to enable your team in conducting FMEA sessions on your products/ processes. We can also develop custom data collection devices that can integrate with your equipment to generate process metrics where needed.