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Industry Forum

Reverse Failure Mode and Effects Analysis (FMEA) Training

Summary

RFMEA process aims to identify and validate all potential failure modes and the controls in Process FMEA and Machinery FMEA, in critical processes first (complaints, high risk) and expand to all lines. Better understanding of new projects, major changes, poka-yoke and mistake proofing devices. Attempts to purposefully generate new defects and challenges existing understanding or ‘expertise’

Duration

1 day

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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: R-FMEA Purpose. 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.

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