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FMEA Investigator Course Outline -- 3 Units

Unit 1: FMEA Overview
Lesson 1: Introduction.
· An overview of what an FMEA is; how the FMEA process works; and why an FMEA is used.
Lesson 2: Purpose of an FMEA.
· An explanation of how an FMEA helps identify risks, prioritizes the risks relative to one another, and focuses efforts on an action plan to reduce the risks.
Lesson 3: Tie to Quality Standards.
· An overview of the links between FMEAs and Quality Standards such as ISO 9000, QS-9000, & TS 16949.
Lesson 4: DFMEA or PFMEA?
· An explanation of the differences between a Design-FMEA and a Process-FMEA.
Lesson 5: The FMEA Process.
· A preview of the 10 steps used to conduct an FMEA. The same basic steps apply to both a DFMEA and a PFMEA.
Lesson 6: Assembling an FMEA Team.
· Helpful hints on assembling an effective FMEA team.
Challenge: An assessment of the learner's progress in this unit.

Unit 2: Design-FMEAs
Lesson 1: Design-FMEA Scope.
· How to clarify the scope for a DFMEA.
· Details on how to use the DFMEA Scope Worksheet.
Lesson 2: 10 Steps to Conduct a DFMEA.
· Step-by-step directions on conducting a DFMEA.
· Guidance on the use of the FMEA Analysis Workshee
t. · Techniques for customizing the Severity, Occurrence, and Detection Ranking Sales for a DFMEA.
Lesson 3: DFMEAs & Control Plans.
· Using the DFMEA Analysis to develop input for a Process Control Plan.
Lesson 4: Getting More Out of Your DFMEA.
· Tips on the best times in a product's life cycle to conduct a DFMEA.
· Tips on how to use the results of an FMEA to trigger continuous improvement.
Lesson 5: DFMEA Example.
· An example of the application of a DFMEA, working through all 10 steps.
Challenge: An assessment of the learner's progress in this unit.

Unit 3: Process-FMEAs
Lesson 1: Process-FMEA Scope.
· How to clarify the scope for a PFMEA.
· Details on how to use the PFMEA Scope Worksheet.
Lesson 2: 10 Steps to Conduct a PFMEA.
· Step-by-step directions on conducting a PFMEA.
· Guidance on the use of the FMEA Analysis Worksheet.
· Techniques for customizing the Severity, Occurrence, and Detection Ranking Scales for a PFMEA.
Lesson 3: PFMEAs & Control Plans.
· Using the PFMEA Analysis to develop a proactive Control Plan.
Lesson 4: Getting More Out of Your PFMEA.
· Tips on the best times and places to conduct a PFMEA.
· Tips on how to use the results of an FMEA to trigger continuous improvement.
Lesson 5: PFMEA Example.
· An example of the application of a PFMEA, working through all 10 steps.
Challenge: An assessment of the learner's progress in this unit.