Design Review Training Based on Failure Modes

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Course Duration: 3 Days - 8 Hours/day

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.

Learning Objectives

· Explain the difference between DFMEA and SFMEA

o 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

o 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

Course Outline

· Course Introductions and Overview

· Chapter 1: Introduction to Design Review Based on Failure Mode (DRBFM)

· Chapter 2: DFMEA and Relationship to DRBFM

· Chapter 3: DFMEA Preparation for DRBFM

o Breakout Exercise 1: Boundary (Block) Diagram

o Breakout Exercise 2: Structural Analysis

o Breakout Exercise 3: Functional Analysis and Failure Analysis

o Breakout Exercise 4: Failure Modes

o Breakout Exercise 5: Failure Net

o Breakout Exercise 6: Design Controls

· Chapter 4: Performing a DRBFM

o Breakout Exercise 7: Identify Design Change and Awareness Sheet

o Breakout Exercise 8: Change Point Summary

o Breakout Exercise 9: Change Point Function Matrix

o Breakout Exercise 10: Perform DRBFM Evaluation

· DRBFM Example on Puddle Light System (presented at SAE World Conference)

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.

Course Materials

Each participant will receive extensive course material.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.


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

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