Course overview
This ‘hands-on’ 1-day workshop is designed specifically for operators involved in the manufacture and fabrication of products. Using examples and case studies participants gain a practical, yet thorough, understanding of the effects of undesirable events on manufactured products and how they may be avoided in the first place.
Analysis of manufacturing and inspection methods
Creation of a Process Flow Diagram (PFD)
Practical risk-based thinking to determine potential failure modes
Determination of root causes and effective countermeasures
Development of a PFMEA from the ground up
Attendees are requested to provide the manufacturing and inspection documentation of a typical product so that the operation steps may be determined, the PFD created, and a full risk analysis undertaken culminating in a PFMEA.
Course details
Understanding ‘risk’ in manufacturing operations –
definition of risk (undesirable ‘events’)
visualizing risk assessment
AS9100:2016 ‘risk-management’ process requirements
responsibilities of a risk management team
Team exercise – undesirable events we’ve experienced!
Reasons for risk identification and avoidance –
safety to operators & end-users
customer impact (quality & delivery)
cost to the company
risk management process stages
cost of quality – focus on prevention
Team exercise – the knock-on effects of undesirable events!
Reviewing manufacturing/inspection documentation –
characteristics of products/services
manufacturing process activities/steps
results to be achieved
Team exercise – identifying and reviewing documentation
Identifying sources of risk in manufacturing –
Process Flow Diagram (PFD)
operation steps (internal & subcontracted)
understanding the terminology (item/requirement/failure mode)
identifying what could go wrong (potential failure modes)
product characteristics & sources of variation
Team exercise – identifying the process flow and creating a PFD
Understanding and quantifying risk –
severity of the consequences (RAG)
likelihood of occurrence (RAG)
Team exercise – quantifying our undesirable events!
Zeroing-in on cuses and their likelihood –
understanding the terminology (Cause/Likelihood)
overview of root cause diagnostic tools (5-WHYs, Fishbone, FTA & 8-D)
Determining the cause(s) of failure modes –
IAQG’s Fishbone diagram
IAQG’s ‘bones’
Team exercise – identifying causes and quantifying their likelihood
Evaluating existing controls –
understanding the terminology (Controls/Detection)
identifying and classifying existing controls
detection – quantifying the effectiveness of existing controls
Team exercise – identifying, classifying and ranking existing controls
Prioritizing improvements –
calculating the RPN = severity x likelihood x detection
prioritizing necessary actions
RPN and S + L + D
Team exercise – selecting an ‘appropriate’ action threshold
Devising new/improved methods & controls –
strategies to reduce risk
mitigate risk with ‘formal’ problem solving methodology
rescoring the S, O, D – and calculating the ‘new’ RPN
Team quiz – devising/deploying ‘countermeasures’
Recording the risk management process –
the PFMEA ‘worksheet’
understanding the sequence of the PFMEA
Team exercise – populating the PFMEA worksheet
Continual improvement –
monitoring deployment of ‘countermeasures’
re-evaluating severity x likelihood x detection when problems occur
developing 'generic' PFMEAs
Team assignment – identifying and fixing ‘gaps’ in capability
Who should attend
Shop-floor operators and line inspectors involved in the manufacture and fabrication of products.
The course also provides as an excellent introduction to ‘risk-based thinking’ and PFMEAs for individuals planning to attend our 2-day AS13004 - Failure Mode & Effects Analysis & Control Plans course
Deliverables & benefits
Individuals attending this course will receive a training certificate containing the TEC logo which is recognised internationally.
Competency will be demonstrated through the undertaking of all of the individual/team exercises and the populating of a PFMEA worksheet – based on an organization’s own product data.