📌 Introduction
In today’s competitive and quality-driven environment, anticipating and mitigating risks is critical. Failure Mode and Effects Analysis (FMEA) is a structured, proactive tool used across industries to identify potential failures, assess their impact, and implement effective corrective actions. This course equips professionals with practical insights and hands-on tools to enhance reliability, improve quality, and reduce risk in design, process, and service functions.
🎯 Course Objectives
- Understand the significance of FMEA in quality assurance and risk management.
- Learn the types of FMEA (Design, Process, and Service/Software) and their specific applications.
- Master the 7-step FMEA methodology—from planning to documentation and review.
- Identify and evaluate potential failure modes, their causes, and effects using key risk metrics.
- Prioritize risks using Risk Priority Number (RPN) and formulate targeted corrective actions.
- Link FMEA outcomes with control plans and continuous improvement initiatives.
FMEA Landscape
- Design, Process, Functional, System FMEA
- Aligning FMEA with ISO 9001, IATF 16949 & Risk-Based Thinking
- Link between FMEA and Product Development/Change Management
FMEA Process Overview & Methodology
- The FMEA Development Lifecycle: Step-by-step
- FMEA Methodology:
- Failure Modes, Effects, Causes
- Severity, Occurrence, Detection
- Risk Priority Number (RPN) Calculation & Action Thresholds
- Three Path Model: Systematic escalation from function → failure mode → control
- When and how to take action: Developing effective mitigation plans
- The concept of “What is Risk?” and Criticality (S × O)
FMEA in Product Development
- Integration of FMEA in product lifecycle: Concept → Design → Production
- System, Subsystem, and Component FMEAs
- FMEA Timing: When to initiate and when to review
- Real-Life Case: FMEA application in new product launch
Design & Process FMEA Linkage
- How Design FMEA informs Process FMEA
- Special Characteristics: Critical vs Significant
- Defining, Tracking, and Documenting Special Characteristics
- Flow of information from DFMEA → PFMEA → Control Plans
Tolerance Design & Capability Estimation
- Using FMEA outputs for:
- Tolerance stack-up analysis
- Estimating and validating Process Capability (Cp, Cpk)
- Prevention vs Detection mindset in capability improvement
QC Tools – Data-Driven Decision Making
- Strategic use of:
- Pareto Analysis (prioritization)
- Cause & Effect Diagram (root cause mapping)
- Control Charts (process stability)
- Histograms, Check Sheets, Scatter Plots, Flow Charts
- Quality Dashboards using QC Tool insights
- Case Application: Applying QC Tools to reduce non-conformities
Root Cause Analysis – Going Beyond Symptoms
- Why-Why (Vive) Analysis vs 5 Whys
- Fault Tree Analysis (FTA) for complex failures
- Common pitfalls in RCA – How senior leaders can guide correct application
- RCA in post-audit, complaint handling & CAPA
Integrated Problem-Solving Approach
- PDCA and DMAIC frameworks
- Linking RCA → Preventive Action → FMEA Updates
- Leading RCA workshops and decision reviews
COURSE SCHEDULE & FEES
Holiday Inn
Training Session
Bangalore
In-Person Training
14750
Inclusive of all taxes
Holiday Inn,Aerocity
Training Session
Delhi
In-Person Training
14750
Inclusive of all taxes
The Lalit
Training Session
Mumbai
In-Person Training
14750
Inclusive of all taxes
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