This document provides information about a 2-day PFMEA (Process Failure Mode and Effects Analysis) training course offered by TONEX for $1,699. The training will cover the theory, logic, and techniques of PFMEA including how to assess potential process failures, evaluate risk, and prioritize corrective actions. Attendees will learn how to apply PFMEA to problem solving, daily improvement efforts, and will receive techniques to create value-added PFMEAs in less time. The training objectives are to define PFMEA, explain the procedure, evaluate risks, and apply PFMEA in various improvement initiatives.

1. PFMEA Training | Process FMEA Training
tonex.com /training-courses/pfmea-training/
Price: $1,699.00
Length: 2 Days
PFMEA Training By TONEX, Process FMEA Training
PFMEA Training, Process Failure Mode Effects Analysis (PFMEA) Training Course Description
PFMEA training, Process FMEA training course will cover the theory, logic, and techniques behind the process
failure mode and effect analysis procedure.
What is PFMEA?
A Process Failure Mode Effects Analysis (PFMEA) is a systematic analytical methodology adopted by an
organization, business department, or Cross Functional Team (CFT) in order to assess the potential causes of
failures in a process. PFMEA is a useful tool to determine the effect of the failure, and evaluate and prioritize the
reduction risk actions. Process FMEA is used when a new product or a new process is designed. PFMEA is a
practice in which the engineering team evaluates all the possible causes for failure. Such methodology is often
applied at early stage of the process or product development, however it can be beneficial in the daily basis
improvement and problem solving. PFMEA assesses each step of a process and assigns a score of 1 to 10 to its
following variables:
Severity
Occurrence
Detection
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2. RPN (Risk priority number)
TONEX PFMEA training course will teach you what each of the above variable means and they are measured by
PFMEA. Also TONEX PFMEA seminar will help you learn a general template for this procedure, while also teach
you how to tailor it based on your product/process specifications. Students will bring their own examples and using
Tonex PFMEA framework and tools, they are able to analyze their process and measure the failures and risks while
in the class.
During this two-day hands-on seminar, trainees will also learn about the PFMEA applications in the following
matters:
Problem-solving process
Daily improvement
Creating value-added PFMEAs in a shorter time
Identifying operator errors in PFMEA
When using in problem-solving PFMEA demonstrates multiple similarities with Eight Disciplines of Problem Solving
(8D) method. During the TONEX PFMEA training course, we will explain the relationship between PFMEA and 8D
methods and will teach you when to use which.
As mentioned above, PFMEA is used on early stages for initial improvements. However, TONEX PFMEA seminar
will train you how to put this practice into work for your day-to-day improvements also. Once it is used effectively by
a Cross Functional Team (CFT), PFMEA can continue its service to Kaizen or Continuous Improvement teams.
Another benefit of participating in TONEX PFMEA training course is that you will learn the techniques to dramatically
shorten your PFMEA Development activities. Such action occurs through reviewing all the available data and
identifying areas in which the information is new, changed, or affected by the time and environment. During the
TONEX PFMEA workshop, we will train you to capture known and brainstormed failure modes and causes in a user-
friendly worksheet.
Those who have the experiencing of developing PFMEAs can tell you that it is not an easy task. A comprehensive
PFMEA Development is crucial in order to gain value from practice, while it should not be an excessive time
intensive procedure. The TONEX PFMEA seminar will provide you the techniques which help you create a
comprehensive and effective PFMEA at a reasonable amount of time. We will teach you how to collect and
document all the brainstormed and received information into a database so that if the same problem happens, there
won’t be any need to have a discussion and brainstorming session again. Through this useful technique, failure
modes and causes can be reviewed fast to develop a proper PFMEA.
Learn about Four Common Classes of FMEA:
System FMEA: Focuses on how interactions among systems might fail.
Design FMEA: Focuses on how product design might fail.
Process FMEA: Focuses on how processes that make the product might fail.
Machinery FMEA: Focuses on how machinery that perform processes might fail.
Process Failure Mode & Effects Analysis (PFMEA) Operating Scope :
Processes involved in determining of final product characteristics.
Trainees Will Also Learn:
How to incorporate PFMEA into new product development process
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3. How to impress customer and meet organization requirements
Relationships between PFD, PFMEA, Control Plan, SOP
Relationship between PFMEA and 8D
Based on the effects of failure mode, the attendees will identify the severity of the failure mode by using severity-
ranking chart:
PFMEA Input for Preparation
Process Flow Diagram
Drawing & DFMEA
AIAG FMEA manual 4th edition as guideline standard for PFMEA preparation.
PFMEA check sheet for carrying out the PFMEA.
Historical data (e.g. Customer Return / Warranty Rejection, In-house Rejection, Process Capability Report
etc)
Quality and Reliability History
Occurrence matrix and feedback ratio
Approach for making PFMEA.
Identify the potential failure mode of each process and find out the effect of each potential failure mode at the
current operation, next operation(s) and at customer end.
Lesson learned
PFMEA Output
Detection Rating
Occurrence Rating
Severity Rating
RPN Rating
Prevention Method
Detection Method
Recommended action, as applicable
Risk Evaluation
Risk priority number (RPN): Risk Priority number is Severity multiplies by frequency and detection. The use of
an RPN threshold is NOT a recommended practice for determining the need for actions.
（S）X（O）X（D）= RPN
Setting of RPN target
RPN target will be fixed based on the Severity ranking for initiating action on failure mode / causes. The
following RPN Target will be used during PFMEA unless otherwise specified by the customer.
Example approaches to reduce S,O, and D:
To reduce Severity (S) ranking: Only a design or process revision can bring about a reduction in the severity
ranking.
To reduce Occurrence (O) ranking: To reduce occurrence, process and design revisions may be required. A
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4. reduction in the occurrence ranking can be effected by removing or controlling one or more of the causes of
the failure mode through a product or process design revision.
To reduce Detection (D) ranking: The preferred method is the use of error/mistake A redesign of the detection
methodology may result in a reduction of the detection ranking.
Examples of Weld Process Failure Modes
System (Welding Line)
Robot Failure
Loss of Incoming Water
No Signal to Weld
Subsystem (Weld Gun)
Cracked Jaw
Failed Servo Motor
Failed Shunt
Component (Servo Motor)
Overheats
Loss of Position
Premature Seal Failure
Containment Considerations
Cost of Defects
Risk of Defects
Bracketing Strategies
Protecting On-Time Delivery
Cost of Stopping Production
Cost of Recall Campaigns
Benefits of Traceability
Prioritization of Risk
Alternative strategies exist for the mitigation of risk, for example:
High Risk Priority Numbers
High Severity Risks (regardless of RPN)
High Design Risks (Severity x Occurrence)
Other Alternatives (S,O,D) and (S,D)
TONEX Process FMEA training includes many in-class activities including hands on exercises, case studies and
workshops. During the Process FMEA workshops, students bring in their own design work and issues and through
our coaching, develop their own Process FMEA Failure Mode and Effects Analysis (PFMEA).
Learn about the framework, tools and procedures:
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5. Potential FMEA Reference Manual is the authoritative reference.
Severity scores of 9 or 10 must be used for safety related risks.
Occurrence ranks how often each cause is likely to result in failure.
It is appropriate to focus on high severity items first.
Credit for preventive actions shows up in the frequency of occurrence.
Risk Priority Numbers provides a rank order to risks and action items.
An effective approach is to continually focus on the top five concerns.
Process FMEA should result in tangible improvement to process
Audience
TONEX PFMEA training is a one-day course designed for:
Cross functional team members
Internal auditors
Quality team members
New product development managers
R&D personnel
All individuals involved in preparing, reviewing, and maintaining PFMEAs.
Training Objectives
Upon completion of this seminar, attendees are able to:
Define PFMEA
Explain the whole procedure of PFMEA, step by step
Brainstorm potential failure modes
Evaluate risk of failure
Define and evaluate four elements of severity, occurrence, detection, RPN
Apply PFMEA in problem solving
Use PFMEA in daily improvements
Create value-added PFMEAs in half of the time
Address operator errors in PFMEA
Understand and discuss the similarities and differences between PFMEA and 8D
Identify where to use 8D and PFMEA to solve problems
Develop a thorough PFMEA as quickly as possible
Document all the PFMEA information related to each incident
Use the prepared database to run PFMEA for a repeating problem without re-brainstorming and re-discussion
Apply mistake proofing techniques
Course Outline
Overview of PFMEA
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6. PFMEA definition
Elements of PFMEA
Principals of PFMEA
PFMEA team members
What are S/O/D factors and how they are related to RPN?
Severity
Occurrence
Detection
RPN
Applications of PFMEA output:
Process redesign/leaning
Control Plan
Out-of-Control Action Plan (OCAP)
PFMEAAdvantages
Identifying potential failure modes, before occurring
Manufacturing and assembly failures detection
Key process variables detection to control the potential failure causes
Prioritizing the potential failures
Establishing corrective/preventive actions to avoid failures
Identifying critical process properties
Feeding the process control plan
PFMEA Vs. 8D
What is 8D?
Similarities between 8D and PFMEA
Differences of 8D and PFMEA
When to use PFMEA and when 8D?
Prior PFMEA Requirements
Building an effective team
Collect proper people
Organize the people effectively
Assign a separate team to each process
Agreeing on a ranking system
Defining the customer needs and expectations
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7. Define the process requirements and standards
Mapping the baseline process with a flow chart
PFMEA Flow
Creating the team
Mapping the process
S/O/D ranking and RPN calculation
Action plans to reduce the RPN
Actions to resolution
Implementing control systems
Adjusting RPNs
Mapping the Process
Selecting on the process
Defining the scope of the process, the start and the end points
Agreeing on the level of detail usage
Determining the sequence and the steps of the process
Determining the key components of the process
Identifying the main potential failure modes
Analyzing the results
Documenting the data for each step of the process
Developing the Action Plan
When action plan is needed?
Identifying the difference between the current and the desired situation
Identifying the ways to eliminate or reduce the failures
Eliminating unnecessary steps and those that don’t add value to the output
Assess the effectiveness of the design modification on the S/O/D ratio
Document all the data
Re-evaluate the S/O/D and RPN values
PFMEA as Part of ISO9001
Advanced Product Quality Planning & Control Plan
Measurement System Analysis
Process Failure Mode and Effects Analysis
Statistical Process Control
Quality System Analysis
Production Part Approval Process
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8. Tooling and
Equipment Supplement
TONEX PFMEA Workshop and Case Studies
Form a cross-functional team
Select a team leader
Select a process
Define the scope, goals, and timeline of completing the PFMEA
Develop a detailed process map
Transfer the map to a PFMEA template
Assign S/O/D score
Calculate the RPN
Complete a Responsible, Accountable, Consulted, and Informed (RACI) chart for the corrective actions.
Track changes in the process, design, and other key components
Analyze the results
Develop a proper action plan
Process FMEA Training, PFMEA Training
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