FAILURE MODE AND EFFECT ANALYSIS (FMEA)

OVERVIEW

Failure Mode and Effects Analysis (FMEA) is a systematic and proactive methodology used to identify, evaluate, and eliminate potential risks and failures associated with product or process design. By enabling organisations to anticipate issues before they arise, FMEA supports early intervention and preventive action, thereby reducing the likelihood of costly disruptions, safety incidents, and quality deficiencies. This forward-looking approach enhances the overall reliability, safety, and performance of systems and processes, while also contributing to increased customer satisfaction and reduced operational risks. FMEA is particularly useful when analysing the effects of proposed changes to existing processes or evaluating new processes prior to deployment. Rather than addressing problems after they occur, this method supports continuous improvement by allowing teams to prioritise and address failure modes based on severity, occurrence, and detectability.

This two-day course presents a structured, step-by-step methodology for conducting FMEA, guided by proven best practices in both design and process applications. Participants will gain a thorough understanding of how to apply FMEA as a risk assessment and problem-solving tool, learning to identify failure modes, evaluate their impact, and determine appropriate actions to mitigate or eliminate risks. Emphasis is placed on the application of both Design FMEA (DFMEA) and Process FMEA (PFMEA), including preparation, analysis, failure mapping, and rating techniques.

Throughout the course, participants will develop complete FMEA documentation using robustness tools, process flow charts, and control plans. Industry-specific examples and terminology will be used to ensure practical relevance and to reinforce conceptual understanding. By the end of the course, participants will be equipped with the knowledge and practical skills needed to implement FMEA effectively within their own organisations to drive design improvement, enhance process management, and reduce failure-related costs.

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 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 1,480.00 nett per participant

Group Registration – RM 1,110.00 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 sales@progresslink.com.my
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.

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