Training Program Reverse Process FMEA (duration: 2 Days)

Transcription

Training ProgramReverse Process FMEA(duration: 2 days)Teaching Objectives:Organization/Means: Training delivered by trainer with 20 years ofexperience of risk Analysis, reliability analysis,statistical analysis in the automotive industry. To insure maximal implication of the traineesand optimal efficiency, this training isseparated in a first part consisting oftheoretical courses and exercises, followedby a day of Reverse PFMEA workshop/audit,carried out by the participants, with themoderation of the trainer, directly on one ofthe production lines of the company whoorganizes the training. The theoretical course and exercises areorganized in a dynamic and interactivemanner (questions, interactions). This is sothat exchanges between the trainer and theparticipants are maximized (betterengagement of the participants). This training allows to train, at the same time,the participants and the leaders of theinternal reverse PFMEA Process. The leadersperform the animation of certain parts of thereverse PFMEA audit (withmoderation/correction from the trainer). Trainees can access post training supportduring the 6 months following the end of thetraining (answers to questions & problems bytelephone, web meetings, emails). Each participant receives training manuals inEnglish or local language in paper & numericformat, as well as workshop checklists andexercise files in numeric format.Know how to organize, plan and realizeReverse Process FMEAs in agreement withrequirements of IATF 16949 and car makers’& tier 1 suppliers Customer SpecificRequirements relative to Reverse PFMEA:oUnderstand Reverse PFMEA generalprinciple, its benefits for theorganization.oKnow how to apply Reverse PFMEA inan “efficient” and “active” way thanksto techniques that allow: Application of Reverse PFMEAin priority on most criticalprocess steps (mostimportant short term addedvalue). Gain of time by “mutualizing”Reverse PFMEAs on someprocess steps that are uniquein the shop floor or verysimilar from one process tothe other. A long term, regular andfeasible planning of ReversePFMEA in the shop floor.oKnow how to apply Reverse PFMEAsin a way that makes the organizationmore pro-active in: Prevention of Non-Conformsand customer claims. Continuous improvement ofmanufacturing processes.Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

oUnderstand Reverse PFMEAorganization and steps to follow forits realization.oUnderstand Reverse PFMEA workingdocuments and adapt them to thetrainees’ organization, local context &requirements.oConduct a real Reverse PFMEA on oneof the processes of the trainees, onthe shop floor. Carry out thecorresponding PFMEA update andInitiate the resulting action plans.ooUnderstand differences andinteractions between: Reverse Process FMEA andregular PFMEA Updates. Reverse Process FMEA andthe other Quality, Riskanalysis and problems solvingtools. Vertice Engineering realizes, prior to thetraining, a tailoring of the training contents,so that:ooThe theoretical part is adapted toproducts, processes, tools, industrialcontext of the organizing company.The Reverse PFMEA workshop cantake place on one of themanufacturing processes of theorganizing company. Vertice Engineering will precise, prior to thetraining, materials conditions necessary forthe realization of the Reverse PFMEAworkshop/audit on the production line. The participants should come from relevantpluri-disciplinary departments. (Engineering,Maintenance, Quality, Industrialization,Production, Maintenance, Safety, Tooling,Project Management, Purchasing,Management).Know how to trigger and leveragerealization of Reverse PFMEAs inadequate situations in development,industrialization and serial lifeproduction, in agreement with IATF16949 and applicable CSRs.How the results of the training are evaluated: Evaluation Quizz to evaluate the level of eachparticipant, filled by each participant at thebeginning and end of the training.Post training accomplishments evaluations, filledby each participant, along with his hierarchy, 3months after the training.Training quality evaluation questionnaire filled byeach participant, at the end of the training.Targeted audience :Any person who should take part in Reverse Process FMEA or lead the realization of Reverse ProcessFMEA.Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

Pre-requisites: Even though the principles of Process FMEA are reminded in the introduction of this training,participants are required to be familiar with the Process FMEA tool and its basic benefits.Possible training dates & details of organisation :Please contact us contact@vertice-engineering.com to receive information about possible training datesand the details of the organization, in function of the type of training (virtual/in person, incompany/mutualized.Detailed training program:(Exact timing for each part of the training to be detailed after training tailoring period).1. Introduction & theoretical courses and exercises:This « theoretical » part is realized in a dynamic and interactive way. It contains, as much as possible,some animations that lead to questions, interactions between the trainer and the participants. It alsocontains some small application workshop/exercises realized as a working group.1.1 Process FMEA (PFMEA) – Reminders: What is process FMEA. What are its benefits. How does PFMEA operate in project phase and during serial life updates. Different types of FMEA. What they allow and their differences. Efficient/Active approach in PFMEA. Initialization of PFMEA. Usage of PFMEA, early on, on most critical process steps. Main parts of a Process FMEA. Application exercise. Identification, Notation, usage & management of Special Characteristics Quizz.Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

1.2 Introduction to Reverse Process FMEA (Reverse PFMEA): Anticipation of Non-Conforms and Customer claims: Goal of Reverse PFMEA: going fromreactive to pro-active approach by using PFMEA in serial life and at end of project phase,to anticipate & address Non-Conforms instead of treating them in PFMEA after theyhave occurred and potentially generated customer claims (Reduction of visible andhidden Costs of Non Quality). « Gap » between what is anticipated in PFMEA and the real operation of themanufacturing process. Practical benefits and added value of Reverse PFMEA. Method of realization of PFMEAs. Link with some management principles of Toyota (Notably the Gemba approach). Strategy for the implementation of Reverse PFMEA in an efficient and active way, with along term vision/approach.1.3 Workshop to discover and synthetize the OEMs IATF 16949 Customer Specific Requirements (CSR)regarding Reverse PFMEA. Mention of requirement to realize Reverse PFMEAs during project phase.2. Reverse FMEA practical implementation, prioritization of process steps anddefinition of audit plan, adaptation of working documents:This part contains theoretical courses animated dynamically, using questions & interactions, as well asshort “hands on” exercises and workshops.2.1 Practical Implementation of Reverse PFMEA. Team, roles & responsibilities, input information. Usage of Reverse PFMEA Tools: Synoptic and Checklist. Different techniques in order to identify new potential failure modes and new causes. Deduction of Failure Modes from the Effects. Usage of the Reverse PFMEA Checklist.2.2 Prioritization of process steps and definition of audit plan:Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

Analysis of the product/process example chosen as workshop application by thecompany who organizes the training. Remainder of Customer Specific Requirements regarding the Reverse PFMEA audit plan. Prioritization of process steps, definition of the audit plan (Priority on most criticalprocess steps and mutualization of some steps). Planning of actions to be realized during the Reverse PFMEA (tests with real defectivecomponents). Evaluation of Reverse PFMEA analysis time for each process step. Adaptation of available documents (checklist & synoptic) to particular needs of thecompany who organizes the training, if necessary.3. Reverse PFMEA Workshop/Audit on production line Update of PFMEA anddefinition of action plans:This part is conducted as a Reverse Process FMEA audit workshop, directly on the production line,followed by a Process FMEA update workshop and a theoretical course. Advices in order to prepare and animate optimally a Reverse PFMEA audit (as a pluri-disciplinarygroup, in the shop floor). Realization of the Reverse PFMEA audit on the production process chosen by the company whoorganizes the training. Synthesis of elements identified during the Reverse PFMEA audit. Update of Process FMEA following the Reverse PFMEA audit. Definition and planning of action plans during the PFMEA update. Final course: Relationship between Reverse PFMEA and regular PFMEA updates. Final course: Relationship between Reverse PFMEA and other Quality tools (Root cause analysis,QRQC, 8D, Control of non-conforming products, preventive and corrective actions). Final course: Situations in which the Reverse PFMEA is recommendable or imposed.Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

Final course: Benefits associated to switching to a more « pro-active » approach in the view ofimproving manufacturing processes and avoiding Non conforms and customer claims (transfer oftime and resources for treating existing issues to anticipating them. Associated time savings,reduction of associated visible and hidden Non-Quality Costs).Vertice Engineering (INSCENTEC SARL)3, rue de la Touraine 31100 Toulouse, France 33 (0) 5 81 310 282www.vertice-engineering.comSIREN 750 475 337RCS TOULOUSE 750 475 337

Reverse Process FMEA and regular PFMEA Updates. Reverse Process FMEA and the other Quality, Risk analysis and problems solving tools. o Know how to trigger and leverage realization of Reverse PFMEAs in adequate situations in development, industrialization and serial life production, in agreement with IATF 16949 and applicable CSRs. Vertice Engineering realizes, prior to the training, a .