fmea & poka yoke 2 days

8/4/2019 FMEA & Poka Yoke 2 Days

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Productivity & Quality Improvement Program

FAILURE MODE AND EFFECT ANALYSIS (FMEA)AND CONTROL PLAN

AND POKA YOKE DEFECT PREVENTION

OBJECTIVEFailure Mode & Effect Analysis (FMEA) is an established riskassessment methodology to systematically identify the potentialfailure of a product or process, assess the impact of the failure, anddevelop an action plan to eliminate or minimize the impact of thepotential failure by planning the control. FMEA is focuses onprevention, either in manufacturing or the design processes. ThePoka Yoke is the error proofing that should be used to prevent thefailure either in part or process. A well-developed and comprehensiveFMEA together with poka yoke can greatly reduce the cost of poorquality and it is an interactive process, which will continually improvethe quality of your process or product. Shigeo Shingo is credited with

creating the concept of zero defects and the techniques of Poka-Yoke(Japanese for mistake-proofing). The approach seeks to remove thecauses of defects or, where this is impossible, to inspect each iteminexpensively to ensure that it passes the quality threshold - with nodefects.

 This course will provide participant with the skills• To provide methodology for developing and implementing theFMEA• To present the evaluation criteria for FMEA. Participants wouldable to:

i. Hands-on experience on how to develop a full FMEA andPoka Yoke from scratch

ü Integrate FMEA and Poka Yoke as part of the organizationongoing improvement initiatives

At the end of the training session, the participants will be assessedtheir ability to develop the most effective FMEA as been guide in theAIAG FMEA manual.

COURSE CONTENT & TIMETABLEDay 19:00 Introduction to FMEA

Overview of Quality Function DeploymentCFTBlock Diagram & FTA

10:30Break10:45Developing Design FMEA & Process FMEA

Designing & understanding evaluation criteria12:30Lunch13:30RPN calculation

New ranking table for severityNew ranking table for occurrence

New ranking table for detection

15:30Emphasis on RPN thresholdAssigning process and product control

8/4/2019 FMEA & Poka Yoke 2 Days

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 Through error proofing (Poka Yoke System), Quality controlsystem and Inspection system

16:00Workshop

05:00End

Day 2

09:00Linking FMEA and Poka YokeAssigning process and product control through error proofing(poka yoke system), quality control system and Inspectionsystem

10:30Break10:45Background of Poka-Yoke Methodology12:30Lunch13:30Poka-Yoke: Regulatory Functions

Poka-Yoke: Setting FunctionsPoka-Yoke: Inspection Method

15:30Implementation of Poka-Yoke System

Brainstorming16:00Poka yoke documentation

Case study and group discussion05:00EndFOR WHOM

  This course is designed for front line managers, engineers orexecutives to become experts in the Failure Mode & Effect Analysis(FMEA) activities and Poka-Yoke (mistake-proofing) part of theirquality improvement initiatives.