System FMEA / DFMEA / DVP&R / Characteristics Linkage

Seminar Content

This three-day, hands-on seminar is intended to offer insight into, and hands-on experience with, the linkages between various aspects of the Advanced Product Quality Planning (APQP) process. Specifically, the development and linkage of Block Diagrams, Interface Matrix, System and Design FMEAs and Design Verification (Test) Plans (DVPs) are addressed.

SFMEAs are performed during the Design phase of APQP for Risk Management and Prevention. SFMEAs are used to identify Special Requirements, Critical Items and Key Characteristics to assist in the flow-down to sub-assemblies and components.

This seminar includes breakout exercise sessions using an example of appropriate complexity so that the participant has the opportunity to grasp both System FMEA and Design FMEA concepts. The key part of the course is applying the concepts during the breakout sessions.

Who Should Attend

This seminar is designed for Program Managers, Project Managers, Design Engineers, Quality Managers, Quality Engineers, APQP Team Members, and all other Risk Management personnel.

Recommended Training and/or Experience

Participants should possess a working knowledge of quality systems and methodologies.

Seminar Materials

Each participant will receive extensive course material.

Seminar Goals

  • Explain the difference between DFMEA and SFMEA
    • Demonstrate an ability to properly construct a Boundary (Block) Diagram
  • Explain the use of an inter-relationship matrix to identify relationships between components and higher level systems
  • Demonstrate an ability to properly and effectively complete all items in the DFMEA process
    • Identify Functions, Requirements, Failure Modes, Causes and Controls and properly enter the information in a DFMEA
  • Demonstrate how to use the output from a DFMEA to develop a test plan (DVP&R)
  • Explain how a DFMEA can help identify effects and severity for a process failure mode
  • Identify special characteristics in product design
  • Continual improvements with a focus on the use of Sev, Sev x Occ, and Sev x Occ x Det ratings

Seminar Outline

  • Setting the Stage: APQP Overview
  • Introduction to Failure Mode and Effects Analysis (FMEA)
  • Developing an FMEA
  • Design FMEA Prerequisites
    • Breakout Exercise: Customers and Functional Requirements
    • Breakout Exercise: Boundary Diagram
  • Developing the Design FMEA
    • Breakout Exercise Starting the DFMEA Form
    • Breakout Exercise: Failure Modes
    • Breakout Exercise: Design Causes
    • Breakout Exercise: Design Controls
    • Breakout Exercise: Effects, Severity and Action Plans
  • Characteristics Flowdown
  • Test Planning and Reporting
  • Final Reviews to Confirm Competency