FMEA
Know how to build a first FMEA on a piece of equipment or a shop-floor process: list the possible failures, rate them for severity, occurrence and detectability, then derive an action plan that you follow through to the end.
This course is aimed at team leaders, methods technicians, maintenance and quality managers who are discovering FMEA or who have seen it go by in a customer file without ever having led one themselves. It treats FMEA as a shop-floor project, not as a documentary deliverable.
By the end, you will know how to scope an FMEA, bring together the right team, fill in the failure mode table, rate criticality with grids defined in advance, set an action threshold and re-rate after implementation. The running example is a stamping press and its packaging line, with figures tracked from one step to the next.
What you will be able to do
- Explain in one sentence what an FMEA is, its three variants (product, process, equipment) and in which situations to launch one.
- Prepare an FMEA project: scope, functional analysis, cross-functional team, historical data to bring along.
- Fill in an FMEA table line by line: element, function, failure mode, effect, cause, current means of detection.
- Rate severity, occurrence and detectability with written grids, calculate criticality and set an action threshold.
- Build an action plan that acts on one of the three factors, follow it up, then re-rate only on the actions actually completed.
The path
- The failures you discover too late 4 min
- Frame the project before filling in a single cell 4 min
- Listing failure modes, their effects and their causes 5 min
- Scoring severity, frequency, detectability 5 min
- Act on one factor, then re-score 4 min
Prerequisites
No prior Lean tool required. Knowing a piece of equipment or a line in your workshop is enough. Having the breakdown or scrap history for the last six months on hand makes the exercises easier.
The closing quiz
The topic ends with a 7-question quiz, and a certificate is issued on success.