FMEA: Failure Mode and Effect Analysis (QMS107)

22 August 2017 - 23 August 2017

INTRODUCTION
A workshop that focus on the design and process risk analysis. The workshop helps the participants to perform the proper Risk Analysis on any product or process. Both Corrective and Preventive Actions should be implemented if there are high risk factors or area based on RPM computation. It also exploits and disseminates the appropriate and proper tools for Process Control Plan and documentation. A general procedure for performing and documenting the FMEA process will be given. The roles and responsibility of various functional groups will be deliberated during the session and established for future references.

OBJECTIVES
This session enable the participants to:
• Understand the appropriate Procedures to perform Risk Analysis for a Process or Design
• Construct the right FMEA table
• Document the FMEA and transfer to the appropriate Control Plan for Manufacturing
• Manage and facilitate cross functional groups in performing FMEA Analysis
• Know and appreciate the importance of setting Right Control plan in ensuring product quality and process Capability
• Ensure Product and Process quality in Proactive Manner

COURSE OUTLINE
MODULE 1: GENERAL INTRODUCTION
• The Worldwide Effort of Re-engineering
• Global Competition in Business Development
• Customer's Requirement, Audit and Quality Improvement
• The Quality and Reliability Aspects of Products
• Basic Definition of Risks Associated with a Product, Design and Process
• Tools for Assessing and Remedying Risks
   - Fault Tree Analysis
   - Redundancy Circuit or Flow
   - FMEA Studies

MODULE 2: FMEA METHODOLOGY
• Different Types of Approach in Managing a Process
   - Reactive Methods -- Fire Fighting
   - Proactive Approach
   - Corrective and Preventive Actions
• Risk Analysis of a Process/Design
   - Critical Failures. -- Assignment of Rating and Examples
   - Major Failures. -- Assignment of Rating and Examples
   - Minor Failures. -- Assignment of Rating and Examples.
• Process Flow Charts
   - Use of Appropriate Symbols
   - Construction of Process Flow Charts (Exercises)
• Design and Process FMEA
   - The Differences
   - Examples of Design and Process FMEAs
   - FMEA Meetings -- Who, When, How, Why and What needed to exist
   - Fault Tree Analysis. (FTA) -- Application to determine the various routes of failures
• Gap Analysis for FMEA 4th edition compare to previous edition

MODULE 3: TOOLS THAT CAN BE APPLIED WHILE DOING FMEA STUDIES
• Identifying Root Causes
• Problem Solving Techniques
• Analyzing and Writing Operating/Manufacturing Procedures
• Poka Yoke (Mistake Proof) Methods

MODULE 4: DESIGN FMEAS
• The Arts of identifying Failure Modes
• Risks on Failures of Products
• Measures of Severity, Frequency and Detection
• Interaction Effects
• Design Controls
• Examples and Workshop on Design Analysis based on your company's product application and customer's requirement
• Roles and Responsibilities of every member in Design FMEAs

MODULE 5: PROCESS FMEAS
• Identifying process failure modes
• Assigning Severity, Frequency and Detection Ratings
• Process Control Guidelines
• Developing Corrective and Preventive actions
   - Definition of Corrective and Preventive Actions
   - Developing effective Corrective and Preventive Actions
   - Tools applicable during development of Corrective and Preventive Actions
   - Correct method to write Corrective and Preventive Actions in Process FMEAs
• Examples on Process FMEAs
• Workshop on Real Life Process FMEA Applications

MODULE 6: TRANSFERRING FMEA RESULTS TO CONTROL PLAN
• Example of control plans
• Regular Audit Procedures
• Exercise and workshop

MODULE 7: LINKAGE BETWEEN FMEA AND QFD
• What is QFD?
• When, Where, Who, How, What and Why of QFD
• General Examples

MODULE 8: GENERAL DISCUSSION
• Composition of FMEA Team & Members' roles and responsibility
• Managing Team and Maintaining Team morale
• TS16949 requirements for FMEA usage
• General Discussion

METHODOLOGY
The course will be conducted in the form of Workshop, Lectures, Case studies, practically design the FMEA for participant's application and examples.

WHO SHOULD ATTEND
All Personnel involve in R & D, Quality, Production and also those in Marketing and Sales.

TRAINER’S PROFILE
SABRINA LIM has a Bachelor in Engineering (First Class Honours) from The University of Sydney. She was attached to well-known American MNCs where she had hands-on experience in the Quality, Quality Systems and Process Engineering.
Her success in her career include ISO9000 recertification, taking responsibility for product transfer from the US, troubleshooting new product quality problems and involvement in in-process yield improvement programmes, developing training materials, calibration systems, new product specifications and standard operating procedures.
She has been involved in teaching and training for the past nine years and has conducted trainings in quality, quality systems and technical areas. Her hands-on experience in manufacturing as well exposure in training personnel from diverse industries in Malaysia and Singapore enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.

SIM LAM THONG (TQC & TPM, 5S/6S, Project Management Consultant) has more than 23 years of vigorous involvement in TQC/TPM/5S/6S activities, Statistical Application, GD&T, Problem Solving and Project Management training. He has a lot of "Hands on" and practical experience on SPC/ SQC/ QCC/ TQC/ TPM/ TS16949 implementation, statistical application for industry’s measurement and part tolerancing, 5S/TQC/TPM audit and providing in-house consultation services to many local and overseas companies.
He specializes in Quality, GD&T, 5S/6S, TQC, SPC, 6σ quality implementation, Productivity and TPM training/consultation, Industrial Statistics Application and Design of Experiments Training and implementation. He has vigorously involved in implementing and developing 5S/TQC/QCC/TPM Activities in many local multinational and has presented many technical working papers in local and international Quality Conventions such as ICQCC in Hong Kong, Japan and others. He has been conducting training for many multinationals such as Renesas Semiconductor, Hitachi Metals, Hitachi Consumer Products (KL), ICI Products (M) S/B, Hewlett Packard, Acer Computers, Mabuci Motors, VDO, B Braun Medical Industries, Fairchild Semiconductor, Motorola Penang, ACM Chemical, Seagate Penang, Hong Yuen (Hong Kong) and many local companies such as Daibochi (M) S/B (Melaka), Malaysian Rubber Gloves, Belton Industries etc. He has also help Hitachi Semiconductor and Hewlett Packard (M) S/B won the Malaysian National Champion in National QCC Convention in 1995, 1996 & 1997.
Prior to working as a consultant he has been working as a TPM/TQM Manager for a large multinational company for 12 years. He has been actively working with engineers to solve engineering and designing problems and application of statistics.
He is currently the TQC/TPM, 6σ Quality, Statistics, 5S and Management Consultants for Shin Etsu Handotai (Shah Alam), Osram, On Semi, Agilent, Samsung Corning, Unisem, Linear Semiconductor, Tessy Plastics (Shanghai), Diethlm Aluminium Works (Singapore), Matsushita Electronic Motor, Renesas, Seagate Penang, Carsem Semiconductors and TFP Plastics. Areas covered including Total Productive Maintenance (TPM), TQC, Measurement Uncertainty & Calibration implementation, Statistical application for 6 sigma and Continuous Improvement. He has also been a 5S consultant for Malayan Flour Manufacturing (MFM) Groups of companies.
He possesses a B.Sc. Ed. (Hons.) (Mathematics/Physics) and M. Sc. (Taguchi Experimentation) both from USM, Penang. He can communicate in English, Bahasa Malaysia and Mandarin with major dialects such as Cantonese and Hokkien.

MS PF LAI has a Bachelor in Engineering (2nd Class Upper Honours) from The University of Malaya. She was attached to well-known Local Contract Manufacturing Company for the last 11 years where she had hands-on experience in the Quality, Quality Systems and Process Engineering.
Her success in her career include ISO9000 certification, TPM implementation, taking responsibility to develop quality systems for various procedures and involvement in in-process problem solving and yield improvement programmes, developing training materials, measurement and evaluation systems, new product specifications and standard operating procedures.
She has been involved in teaching and training for the past 11 years and has conducted trainings in quality, quality systems and technical areas. Her hands-on experience in manufacturing as well exposure in training personnel from diverse industries in Malaysia enables her to provide a good insight to troubleshooting process problems and improving overall quality as well as latest developments in the quality arena.
Below is list of more popular trainings she conducted currently:
1. 8D
2. FMEA
3. SPC
4. DOE
5. Practical Statistical Application in Industry.
6. Quality Tools

DURATION
2 days @ 9am-5pm

COURSE FEE
Program 100% Claimable under SBL Khas and SBL Scheme
PSDC Members: RM 690/pax
Non-Members:   RM 750/pax

*All prices listed above are subjected to GST effective 1st April 2015