Summary
How robust is your PFMEA? The Reverse FMEA process aims to identify and validate all potential failure modes and the controls in either a Process FMEA or a Machinery FMEA. It focuses initially on critical processes first (complaints, high risk) but can be expanded to cover all process steps. This leads to a better understanding of new projects, major changes, poka-yoke and mistake proofing devices. It also attempts to purposefully generate new defects and challenge existing understanding.
Duration
0.5 day
Description
Reverse FMEA is a method of analysis, requested by more automotive OEMs for continuous improvement of product quality.
Appling the method will:
- Ensure the documented PFMEA reflects reality on the shop floor.
- Detect missing or ineffective controls, undocumented risks, or operator workarounds.
- Strengthen compliance with requirements and support best manufacturing practice.
- Align PFMEA with actual process conditions
Who should attend?
Quality Engineers, Manufacturing/Process Engineers, NPI Engineers, Internal Auditors, PFMEA owners, Control Plan owners.
Course Outline
It frequently uncovers hidden operator workarounds, false assumptions, and ergonomic gaps that PFMEAs miss. It strengthens both process discipline and the accuracy of the PFMEA. The most common weak point revealed by RFMEA is detection controls are less effective than the PFMEA assumed.
Benefits and Learning Objectives
Benefits: Effective usage of this tool will:
- Reduce NC’s
- Reduce Waste
- Reduce Scrap
- Improve Customer Satisfaction
- Improve Launch Performance.
Learning Objective:
- Purpose of R-FMEA
- When to Perform R-FMEA
- Methodology (step-by-step)
- Deliverables
- Integration with Other Tools
Certification
Upon completion of the course, you will receive an SMMT Quality Management certificate of attendance.
