Introduction to PFMEA (Process Failure Modes and Effects Analysis)     New!

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I.D.# C1360Printable Description
Duration: 1 Day
October 2, 2014 (8:30 a.m. - 4:30 p.m. ) - Portland, Oregon  

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Process Failure Modes and Effects Analysis (PFMEA) is a methodology that is intended to identify risk within a process and define controls and actions to mitigate the risk. A well done PFMEA improves quality, reliability and safety of a process. This course is designed to assist companies in addressing common problems with the application of Process Failure Modes and Effects Analysis (PFMEA) as defined in the new SAE J1739 FMEA Standard. The course will focus on both the methodology (structured PFMEA Process Flow) and provide a road map to address company culture and engineering "mind set." The defined structure and road map will provide an understanding of how to link the Process Flow Diagram (PFD), Process Failure Modes and Effects Analysis (PFMEA) and the Process Control Plan (PCP).

The course addresses common problems such as: inadequate preparation defining detailed process operation steps in the Process Flow Diagram (PFD) and therefore not addressing all steps in the process (Hidden Factory), lack of understanding of product characteristics (output) and process characteristics (input) within the process flow, false starts and rework of PFMEA due to a lack of understanding of process functions, failing to address all process operations in the PFMEA (including outputs and inputs), too much time spent debating ranking systems (potential problems hidden in the Risk Priority Number), a lack of emphasis on prevention controls or early detection of product defects, the lack of understanding of how to complete the Process Control Plan (PCP), and what information is common throughout the PFD, PFMEA and PCP.

Along with addressing the common problems and providing a detailed PFMEA structure, this course defines roles and responsibilities of management, engineers, and facilitators in the new J1739 standard. The course provides examples and formats to help both those familiar with performing PFMEA and new to the PFMEA methodology. The course provides opportunity for participants to develop their own PFD, PFMEA, and PCP by following along with the course and getting feedback from the course instructor (if desired).

Learning Objectives
After completing this program, you will be able to:

  • Identify new PFMEA requirements that must be fulfilled by management
  • Align ideas within the logical framework of the PFMEA worksheet
  • Correctly use Process Flow Diagrams (PFD)
  • Apply new risk assessment evaluation criteria to the PFMEA
  • Apply the PFMEA as a tool in Process Development
  • Identify current problems implementing PFMEA
  • Illustrate the logical framework of the PFMEA Process Map and worksheets
  • Know the definition & purpose of Process Failure Mode and Effects Analysis (PFMEA)
  • Perform all steps in the PFMEA process
  • Use the PFMEA as a tool in Process Development
  • Define the linkage between PFD, PFMEA, and PCP
  • Identify "hidden factories" steps and material handling in PFDs
  • Discuss the linkage of DFMEA and PFMEA
  • Correctly complete Process Control Plans (PCP)

Who Should Attend
Manufacturing engineers, product engineers, quality engineers, supplier quality engineers, validation and test engineers, and FMEA facilitators, trainers and consultants may be interested in the program content. New engineers, advanced and senior engineers who must participate in FMEA, as well as those that manage FMEA activity, will also gain valuable insights.

Topical Outline
Day One (8:30am – 4:30pm)

  • 8:30am: Introduction to PFMEA and Course Objectives
  • 8:40am-9:00am: Step One: Planning
  • 9:00am-9:45am: Step Two: Preparation (PFD)
  • 9:45am-10:00am: Break
  • 10:00am-Noon: Step Two: Preparation (PFD)…continued
  • Noon: Lunch
  • 1:00pm – 3:00pm (Break included): Step Three and Four: PFMEA Analysis
    • Functions from PFD: Failure modes; Effects; Classification; Causes; Controls; Actions; Risk Analysis (S-O-D)
  • 3:00pm – 3:30pm: Step Five: Actions Taken
    • Actions Taken
    • Revised Risk Analysis (Occurrence & Detection)
  • 3:30pm-4:30pm: Step Five: Process Control Plan Development (PCP)
    • Linkage with PFD and PFMEA
    • Define the four sections of PCP
  • Product and Process Information
  • Characteristics: Product and Process & Classification
  • Methods
  • Reaction Plan
  • 4:30pm: How to Audit PFD, PFMEA and PCP and wrap up

Instructor(s): Bill Haughey
Bill Haughey Bill Haughey is a respected consultant and instructor in the areas of Failure Modes Effects Analysis, Design for Manufacturability and Assembly, Design Review Based on Failure Modes, Design Review Based on Test Results, and other GD3 methodologies. He is a current member of the issuing committee of the SAE J1739 FMEA standard, SAE Automotive Quality and Process Improvement Committee; the SAE Automotive Electronic Systems Reliability Standards Committee; and the AIAG FMEA Fourth Edition Recommended Practice Committee. Mr. Haughey was recently approved to lead the development of a new SAE DRBFM Recommended Practice (J2886). Mr. Haughey formerly worked for GM, where he held various managerial, manufacturing, and engineering positions including Process Lead and Supervisor for FMEA and DFM/A. While at GM, Mr. Haughey also supported Tatsuhiko Yoshimura in the global implementation of the GD3 (DRBFM) methodology. Yoshimura considers Mr. Haughey to be a subject matter expert in the GD3 methodologies, including DRBFM and DRBTR. Mr. Haughey received a B.S. degree from the University of Michigan and M.S from Central Michigan University, and has the following certifications: Black Belt in GD3 (DRBFM and DRBTR); Master Design for Manufacturability and Assembly Engineer; and Certified Internal Auditor.

Fees: $755.00 ; SAE Members: $605.00 - $685.00

.7 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

To register, click Register button at the top of this page and submit the online form, or contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.