FMEA / FMECA Course for Facilitators

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FMEA / FMECA allows to identify potential types of failures of a specific piece of equipment and their possible consequences, before commissioning and for operating equipment.

FMEA и FMECA – globally renowned practices that help determine the risks associated with equipment failures, the consequences of these failures and their criticality for the company’s Production and Business as a whole, as well as develop effective measures to mitigate the risks.

Purpose:

Familiarize participants with the FMEA/FMECA process and provide an understanding of all the requirements to organize, prepare and conduct the process in your company. Develop and reinforce the training participants’ skills of independent leadership in FMEA/FMECA process

General Description:

The course will cover in detail all aspects of FMEA/FMECA theoryas a tool for developing strategies to manage the organization’s assets. Within the framework of the theoretical classes, the knowledge will be shared not only about FMEA/FMECA itself, but also about the principles of its organization, procedural documentation of the process, implementation of results, and aspects of communication between the process leader and the analysis participants.
Each unit of theoretical knowledge will be reinforced with a practical exercise. As a part of the practical training, each participant will get their own experience in conducting the process of analysis and communication with the group. All practical classes will be conducted under the guidance of the experienced experts.

Who is this training for:

Chief engineers, technical directors, chief specialists, engineers and heads of production departments and shop repair services, heads and employees of the diagnostics and reliability services.

Program:

1.Evolution of the maintenance systems and the industrial equipment repair.

  • Brief summary of the history of maintenance-related changes
  • Maintenance requirements

2. Fundamental knowledge of equipment reliability

  • Why does equipment fail – phusics of failures
  • 6 models of equipment failures

3. FMEA – Failure modes and effects analysis. Risk analysis in the asset management context.

  • FMEA development, its application in the modern world

4. FMECA – Failure modes, effects and criticality analysis

  • FMECA – expanded FMEA analysis
  • 2 main types of FMECA, choosing the most appropriate one
  • Key stages of FMECA process

5. Establishment of the FMEA/FMECA process in an organization

  • Necessary requirements to the organization and the conditions of a successful process
  • Preparation for the FMECA process establishment in the company, as well as for the conduct of FMECA

6. Conduct of FMEA/FMECA: Asset and its function

  • Asset definition
  • Asset functions definition
  • Primary and secondary functions
  • Functional standards
  • Functional failures: complete and partial
  • Hands-on exercise on definition of assets, their functions and functional failures

7. Conduct of FMEA/FMECA: Failures and their causes

  • Definition of the failure causes
  • Level of cause identification detail
  • Latent failures
  • Check for failure list completeness
  • Hands-on exercise on latent failures detection

8. Conduct of FMEA/FMECA: Failures resuklts and effects

  • Failure effect categories
  • Hands-on exercise on failure causes identification, their results and effects

 9. Conduct of FMEA/FMECA: Recommended actions

  • Types of recommended actions (equipment maintenance strategies)
  • P-F interval
  • Feasibility and economic viability of the actions
  • Efficiancy estimation
  • Hands-on exercise on the recommended actions development

10. Conduct of FMEA/FMECA: Failure effects

  • failure results and effects
  • Failure effect categories
  • Hands-on exercise on failure causes identification, their results and effects

11. Stages of FMEA/FMECA conduct

  • Structure and assessment of the objects (equipment) for analysis
  • Rules of analysis conduct
  • Procedures
  • Information sources
  • Analysis preparation
  • Analysis conduct
  • Plans creation
  • Templates
  • Feedback
  • Reports

12. Hands-on practice in small groupes

  • Documents review, and study
  • Determination of the assets, their functions, functional failures, causes, results, and failure  effects, and assign recommended actions on a stand-alone basis

13. Independent practical work on “real” equipment

  • Equipment inspection, preparation for the analysis
  • Documents review, and study
  • Group formation
  • Hands-on practice for each training participant as an analysis coordinator

14. Independent practical work on “real” equipment. Tried-and-tested results (strategies), further steps

  • Continuation of the hands-on practice when each training participant acts as an analysis coordinator
  • Trainers’ feedback
  • Implementation of FMEA/FMECA results (strategies), tracking of the developed strategies efficiency