FAILURE MODE AND EFFECT ANALYSIS (FMEA)

OVERVIEW

How can organisations identify potential failures before they result in defects, customer complaints, downtime, safety concerns or costly corrective action? How can teams systematically determine which risks require the greatest attention and what preventive actions should be taken? Failure Mode and Effects Analysis (FMEA) is a structured and proactive risk-management methodology used to identify potential failure modes, understand their effects and causes, evaluate risk, and determine appropriate actions before problems occur. Rather than relying on reactive problem solving, FMEA enables organisations to strengthen product and process reliability by anticipating risks during new product development, process design, process changes and continuous improvement activities.

This practical 2-day programme provides participants with a step-by-step approach to developing and applying both Design FMEA (DFMEA) and Process FMEA (PFMEA). Participants will learn how to define the scope of an FMEA, identify functions and requirements, determine potential failure modes and effects, analyse causes and existing controls, evaluate risk using appropriate rating methods, and prioritise improvement actions.

The programme also explores the important relationship between process flow, PFMEA and Control Plan, helping participants understand how risk analysis should translate into effective operational controls. Practical examples, team exercises and industry-based scenarios will be used to strengthen application and decision-making. By the end of the programme, participants will be better equipped to develop meaningful FMEAs that support defect prevention, risk reduction, design and process improvement, stronger controls and continual improvement, while reducing the likelihood and cost of failures reaching subsequent processes or customers.

LEARNING OUTCOMES

By the end of this workshop, participants will be able to:

√  Understand the principles and purpose of FMEA as a proactive risk management and quality improvement tool.

√  Differentiate between Design FMEA (DFMEA) and Process FMEA (PFMEA), including their scope, application, and objectives.

√  Apply a structured, step-by-step approach to conducting FMEA, including preparation, failure mode identification, and risk evaluation.

√  Assess and prioritise risks using severity, occurrence, and detection ratings to calculate Risk Priority Numbers (RPNs).

√  Develop and document complete FMEA worksheets, incorporating robustness tools, process flow diagrams, and control plans.

√  Analyse and interpret FMEA results to identify critical areas requiring corrective or preventive actions.

√  Use FMEA to support design and process improvements, change management decisions, and problem-solving initiatives.

WHO SHOULD ATTEND?

This course is ideal for Product, Process, Test, and Quality Managers, Engineers, Supervisors, Team Leaders, and staff involved in FMEA, APQP, Control Plans (CP), or PPAP. It is particularly relevant for those engaged in product design, process development, or risk management. While no prior FMEA experience is required, a basic understanding of manufacturing or design processes is beneficial.

COURSE BENEFITS

FMEA enhances customer satisfaction and reduces the likelihood of failures by proactively identifying potential points of failure before they escalate into major issues. By addressing risks early in the design or production process, organisations can prevent costly recalls, avoid legal liabilities, and ensure more reliable product performance.

 TRAINING METHODOLOGY

This workshop employs a dynamic, learner-centered approach that blends theory with hands-on practice. Using a mix of interactive lectures, real-world case studies, and collaborative group activities, participants will engage in role-playing scenarios, problem-solving simulations, and peer discussions to reinforce key concepts.

TRAINING PREPARATION      

As this programme will be conducted online via Zoom, participants are required to have a laptop or computer with a stable internet connection. Participants should also ensure that their camera, microphone and speakers are functioning properly to support effective participation, discussion and interactive learning activities during the session.

TRAINING DURATION

Full 2 days training (9:00 am – 5:00 pm)

HRD CORP REGISTERED PROGRAM ID NOS
10001340007

PUBLIC PROGRAM COURSE FEE

Single Registration – RM 1,250.00 nett per participant

Group Registration – RM 950.00 nett per participant

(For 4 participants or more from the same organisation)

(The fee covers training materials, lunch, coffee/tea, snacks, supplementary notes, a detailed training report with assessment and a Certificate of Completion).

IN-HOUSE TRAINING ENQUIRY

For more information regarding our In-House/ Public Program courses, please email us your inquiry at [email protected]
or to speak to our Sales Consultant at + 604- 297 6881 or 011-1289 6881.

For public program schedules, please visit our website: www.progresslink.com.my

Register with us today! Training fees are eligible for claims under the HRD Corp Claimable Courses scheme.

REGISTER ONLINE