More and more companies are recognizing the benefits of FMEA analysis. Executives are increasingly treating them as a tool that brings real benefits, and not just an element of customer requirements. Therefore, a very important factor determining the effectiveness and efficiency of the conducted analyses is the knowledge and skills of both FMEA team members and their moderators.

To meet these needs, we propose a training course entitled: “FMEA – analysis of causes and effects of nonconformities – moderator” containing elements of advanced application of a quality tool – FMEA analysis.

The training is intentionally divided into three stages: a theoretical introduction to FMEA, then conducting a model moderated workshop for a selected process or structure and, finally, verification of independently performed analysis with particular emphasis on improvement in the approach to documenting FMEA.

In the first part of the training, the basics of conducting an FMEA will be recalled, along with details at an advanced level. The analysis will be presented against the background of current standards (including AIAG, VDA or CSR manuals). Participants will practice defining defects – resulting from both function, product characteristics and process characteristics (special situations).

Principles for defining and assessing the impact of failures on various stakeholders (derived from best practice) will be discussed.

The next training element discussed will be the issue of proper scoring of risk assessment components. When conducting FMEA, it is very important that the amount of the incidence assessment is based on real data, so methods based on statistics that allow to make this value more realistic will be discussed and practiced.

Another issue that is sometimes problematic when conducting analysis is distinguishing between detection and prevention activities and correctly assessing detectability. Therefore, the training will highlight this and show “best practices” for defining these elements of analysis. It will be shown how to link DET assessment to MSA and how to include Poka-yoke solutions in the FMEA worksheet. Participants’ attention will also be drawn to the final risk assessment: the answer to the question “When is risk high?” will be developed.

Additional indicators and ways of assigning priorities for action will be introduced, such as SOD, Pareto analysis, O/S and O/D matrix, or the AP indicator proposed in the draftee of the new manual issued by AIAG and VDA, among others. An important element will also be the presentation of the rFMEA analysis.

Another aspect that will be covered is the combination of FMEA analysis with other system documents (including control plans or process flow diagrams) and the most common audit nonconformities in this area.

The third part of the training is devoted to developing the soft skills of a team leader developing FMEA analyses. Participants will see what elements of people management are important in a facilitator’s work and how to manage a team. The last part of the training is a moderated workshop. Data provided by the training participants can also be used in this part.

We invite everyone interested in taking part in the training to read the detailed program and to sign up.

 

Tomasz Greber Ph.D. (consultant and trainer, Managing Partner) 

For more than 20 years, he has worked on issues related to quality and environmental management systems, statistical methods in quality management, risk management, work organization, audits and surveys, KAIZEN/Lean and Six Sigma approaches. Implements and improves management systems, conducts training for first, second and third part auditors. Moderates workshops of groups dealing with risk analysis in production, trade and logistics processes. He conducts trainings, workshops and consults companies in various industries. He is a lecturer at state and private universities and postgraduate programs. Speaker at many conferences related to management topics.

He is an expert of the Dolnośląska Nagroda Jakości, long-time editor-in-chief of the “Quality Management” magazine, member of the Steering Board of the certification body, auditor of quality management systems. He publishes in magazines: Zarządzanie jakością, Normalizacja, LAB, Problemy jakości, Computerland and in conference publications. He is the author of the books “FMEA Analysis. Compendium of Practical Knowledge”, “Statistical Process Control – Quality Improvement with STATISTICA Package” and co-author of the book “Quality Management in the Process of European Integration”.
He has extensive experience in quality management confirmed by many completed projects and numerous publications in this field. He conducts projects in Polish and English.