RFMEA - Reverse Failure Mode and Effect Analysis

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Course Duration: 2 Days - 8 Hours/day

This two-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 the PFMEA to the Reverse FMEA

RFMEAs are performed after production launch for Risk Management and Detection. RFMEAs are used to identify critical areas in the process and the preventive controls to detect failures to assist in the flow-up to assure the control plan detection methods are effective.

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

A third day is recommended to apply the techniques to a participant's own process.

Learning Objectives

  • Explain the difference between DFMEA and RFMEA
  • Demonstrate an ability to properly construct a RFMEA check-sheet
  • Demonstrate an ability to properly and effectively complete all items in the RFMEA process
  • Identify high risk areas, evaluate and test control plan gaging and measurement.
  • Demonstrate how to use the output from a RFMEA to identify additional risk and work it back into the PFMEA
  • Identify special characteristics in product design and assure that the control methods are effective.

Course Outline

Day 1

  • Intro to FMEA
  • APQP and FMEA
  • Development of a good conventional PFMEA
  • VDA PFMEA 7 Step Process
  • Intro to Reverse - FMEA
  • 7 Step Reverse Process
  • Assemble Malfunction team
  • Review of PFMEA, Develop a Plan

Day 2

  • Development of Reverse FMEA check-sheet
  • Go and See - Evaluate process using check-sheet
  • Evaluate detection method through testing
  • Re-access risk
  • Develop action plan
  • Reporting Results to Customer
  • Continuous improvement- Updating Baselines and Requirements

Day 3 (Optional)

  • Work on in-plant example

Who Should Attend

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

Course Materials

Each participant will receive a course manual.

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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