DRBFM & PFMEA Workshop Focused on Connecting Customer Expectations to Design & Process Requirements     New!

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I.D.# C1361Printable Description
Duration: 2 Days
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This two-day training will explain all phases of the DRBFM and PFMEA methodology and provide details on how to accomplish the specific steps.

With the Design Review Based on Failure Modes (DRBFM) and Design Review Based on Test Results (DRBTR) Process Guidebook that is bundled with the course, the instructor will provide specific information on each step. Formats, examples, notes and homework slides will be used to illustrate the defined steps of the SAE J2886 DRBFM Recommended Practice and the AIAG DRBFM Reference Guide. Similarities in content between DRBFM and FMEA will be discussed; however the focus will be on conducting DRBFM methodology.

This DRBFM training will provide roles and responsibilities of management, design engineers, manufacturing engineers, DRBFM and technical experts. Those interested in DRBFM will benefit from understanding the rationale behind this methodology and learn to guide teams through the paradigm shifts and mind-set that are needed. Those interested will learn how DRBFM supports the activity of the engineer, company objectives and customer expectations.

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).

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:

  • Outline the fundamental steps of DRBFM methodology, including:
    • An understanding of the DRBFM Culture
    • DRBFM Plan and analysis requirements
    • Necessary preparation feeding DRBFM analysis
    • The two phases of DRBFM analysis
    • Documentation of design, validation and manufacturing actions
    • Feedback loop into engineering knowledge documents
  • Explain the intent and format of the DRBFM worksheets
  • Predict what it takes to gain and maintain proficiency and consistent application of the methodology
  • Locate answers to most DRBFM questions
  • 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
Product engineers, manufacturing engineers, quality engineers, supplier quality engineers, validation and test engineers, and facilitators, trainers and consultants in all industries. This seminar will benefit new engineers, advanced and senior engineers and managers who must participate in or manage FMEA's and DRBFM.

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

  • 8:30am – 9:00am: Introduction and course objectives
    • DRBFM Process Competitive Assessment - Toyota Process
  • 9:00am-9:45am: Step One: Preparation Documents
  • 9:45am-10:00am: Break
  • 10:00am-11:15am: Preparation Documents Exercise and Review
    • Participants can bring either DFMEA or DRBFM foundation documents of a current project (boundary diagram, functions and specifications, changes and current issues) for review during this session
  • 11:15am-Noon: Step Two: Change Point Analysis
    • How to complete DRBFM analysis
    • Forum One: Change Point Detail and Functions - System, Sub-system and component
  • Noon: Lunch
  • 1:00pm – 3:30pm (Break included): Change Point Analysis…continued
    • Forum One: Document Change Point Analysis (each student): Concerns; Causes; Effects; Importance; Design Countermeasures; Actions to gain knowledge - Defined by engineer
  • 3:30pm – 4:30pm: Step Three: Design Review and Step Four: Action Results
    • Including an introduction to Design Review Based on Test Results
  • 4:30pm How to Audit your DRBFM and Wrap up

Day Two (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: $1300.00 ; SAE Members: $1050.00 - $1170.00

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

For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at CustomerService@sae.org.