Failure Mode & Effects Analysis (FMEA) Certification

Module 1: Fundamentals of FMEA

• Purpose of FMEA
• Failure prevention
• Risk-based thinking
• FMEA terminology
• Business applications
• Benefits of FMEA

Module 2: FMEA Methodology

• FMEA framework
• Structured risk analysis
• FMEA lifecycle
• Team responsibilities
• Analysis sequence
• Documentation requirements

Module 3: Types of FMEA

• Design FMEA
• Process FMEA
• System FMEA
• Service FMEA
• Application differences
• Selecting the appropriate FMEA

Module 4: FMEA Planning & Preparation

• Defining objectives
• Establishing scope
• Selecting team members
• Gathering information
• Setting boundaries
• Preparing analysis

Module 5: Structure Analysis

• System structures
• Process structures
• Process flow
• Components
• Interfaces
• Relationships

Module 6: Function Analysis

• Functions
• Requirements
• Inputs and outputs
• Performance expectations
• Customer requirements
• Functional relationships

Module 7: Failure Mode Identification

• Potential failures
• Functional failures
• Process failures
• Product failures
• Failure statements
• Failure documentation

Module 8: Failure Effects Analysis

• Local effects
• System effects
• Customer effects
• Operational consequences
• Quality impact
• Effect documentation

Module 9: Severity Evaluation

• Severity criteria
• Rating scales
• Customer impact
• Operational impact
• Safety considerations
• Severity scoring

Module 10: Failure Cause Analysis

• Potential causes
• Failure mechanisms
• Process causes
• Design causes
• Human factors
• Cause-and-effect relationships

Module 11: Occurrence Evaluation

• Occurrence criteria
• Frequency
• Historical information
• Failure probability
• Rating scales
• Occurrence scoring

Module 12: Prevention Controls

• Existing controls
• Error prevention
• Process controls
• Design controls
• Standard procedures
• Control effectiveness

Module 13: Detection Controls

• Inspection
• Testing
• Monitoring
• Verification
• Detection capability
• Control effectiveness

Module 14: Detection Evaluation

• Detection criteria
• Detection probability
• Rating scales
• Control capability
• Detection scoring
• Rating consistency

Module 15: Risk Priority Number (RPN)

• RPN methodology
• Severity × Occurrence × Detection
• RPN calculation
• Risk ranking
• Interpretation
• RPN limitations

Module 16: Action Priority

• Action Priority principles
• High-priority risks
• Medium-priority risks
• Low-priority risks
• Risk prioritisation
• Decision-making

Module 17: Risk Reduction Actions

• Recommended actions
• Preventive actions
• Detection improvements
• Responsibility assignment
• Target dates
• Action tracking

Module 18: Design FMEA (DFMEA)

• Design functions
• Design failure modes
• Design effects
• Design causes
• Design controls
• Risk reduction

Module 19: Process FMEA (PFMEA)

• Process steps
• Process failure modes
• Process effects
• Process causes
• Process controls
• Process improvement

Module 20: FMEA & Control Plans

• Control plan fundamentals
• PFMEA linkage
• Critical characteristics
• Control methods
• Inspection requirements
• Control plan updates

Module 21: FMEA Review & Improvement

• Periodic reviews
• Action verification
• Reassessment
• Residual risk
• Lessons learned
• Continuous improvement

Module 22: Practical FMEA Application

• Define an analysis scope
• Identify failure modes
• Analyse effects and causes
• Assess risks
• Develop improvement actions
• Review remaining risk