PROCESS FAILURE MODE EFFECTS ANALYSIS (PFMEA)
Course Introduction
Process Failure Mode Effects Analysis (PFMEA) is a structured approach to identify, evaluate, and reduce potential failures within a process. By analyzing human error, equipment malfunction, unsuitable methods or materials, and production bottlenecks, PFMEA helps organizations improve reliability, prevent costly errors, and optimize operations.
This program emphasizes practical application across industries, enabling participants to use PFMEA for new processes, modifications, continuous improvement, and preventive maintenance planning.
Objectives
- Understand PFMEA concepts, applications, and benefits.
- Learn how to identify potential process failures and their effects.
- Apply the 6M framework (Man, Machine, Method, Material, Measurement, Mother Earth).
- Develop PFMEA documentation: inputs, check sheets, risk ratings (S, O, D, RPN).
- Use PFMEA for risk evaluation, prevention methods, and mitigation planning.
- Gain tools to improve process reliability, safety, and efficiency.
- Support continuous improvement, Kaizen, and COQ (Cost of Quality) initiatives.
Who Should Attend
- Managers, Engineers, Supervisors, Leaders involved in process management.
- Personnel tasked with quality, reliability, and operational excellence.
- Anyone interested in applying PFMEA for process improvement.
Lessons Module
Day 1
- Ice Breaking & Introduction to PFMEA
- PFMEA Inputs & Process Flow Diagram
- PFMEA Check Sheet & Historical Data (Customer Return, Warranty Rejection)
- Risk & Its Management, Group Presentation
- In-house Rejection & Process Capability Report
- Quality & Reliability History
- Occurrence Matrix & Feedback Ratio
- Fishbone Diagram, Potential Root Cause Analysis
- Day 1 Recap & Closing
Day 2
- Approach for Developing PFMEA
- Identifying Potential Failure Modes & Effects
- Group Presentation
- Detection, Occurrence & Severity Ratings
- Risk Priority Number (RPN) Analysis
- Recommended Actions & Mitigation Planning
- Risk Evaluation & Reduction of S, O, D
- Setting RPN Targets & Action Plans
- Group Presentation
- Day 2 Recap & Closing
Benefits
- Improved risk management & process reliability.
- Better preventive maintenance planning.
- Reduced waste, errors, and downtime.
- Strengthened continuous improvement & cost efficiency.
- Practical tools to apply PFMEA in daily operations.
- 2 Days Programme
- 9:00am to 5:00pm
Training & Workshop Methodologies
- Interactive Lectures
- Group Discussions
- Case Studies & Exercises
- Video Sharing & Presentations
