Failure Mode and Effects Analysis

Programme Summary

This programme develops a structured approach to anticipating product and process failures before their effects reach customers or operations. Participants build an FMEA from functions and requirements through failure mechanisms, existing controls and prioritised improvement actions. Practical exercises emphasise consistent technical reasoning, cross-functional input and follow-through, helping teams create a useful risk-control document rather than an isolated scoring spreadsheet.

Training Objectives

1 Strengthen proactive identification of potential failure mechanisms; 2 Connect functions failures effects and causes logically; 3 Develop consistent risk evaluation and prioritisation; 4 Improve prevention detection and action ownership; 5 Integrate FMEA updates with process control learning.

Learning Outcomes

1 Define a focused FMEA scope and structure; 2 Construct a coherent function and failure analysis; 3 Evaluate risk using suitable rating criteria; 4 Prioritise actions with accountable verification arrangements; 5 Update FMEA findings and linked control documents.

Target Audience

Quality Engineers; Process Engineers; Design Engineers; Manufacturing Engineers; Reliability Engineers; Cross-Functional FMEA Facilitators.

Target Industries

Automotive Components; Industrial Manufacturing; Medical Devices; Electronics; Aerospace Supply; Packaging Manufacturing.

Course Contents

• Module 1 FMEA Purpose Planning and Preparation: Design process and system FMEA distinctions; Scope boundaries team roles and assumptions; Analysis objectives and required technical inputs.
• Module 2 Structure Analysis: Product hierarchy or process-step breakdown; Interfaces interactions and boundary conditions; Linking analysis levels and relevant elements.
• Module 3 Function Analysis: Functions requirements and performance expectations; Measurable characteristics and intended behaviours; Connecting functions across system levels.
• Module 4 Failure Analysis: Failure modes effects and causes; Failure chains and technical consistency; Existing prevention and detection controls.
• Module 5 Risk Analysis and Prioritisation: Severity occurrence and detection evaluation; Action Priority and applicable methodology selection; Limitations of numerical risk comparisons.
• Module 6 Optimisation and Risk Reduction: Prioritising prevention and design improvement; Assigning actions owners and target dates; Evaluating implemented controls and residual risk.
• Module 7 Results Documentation and Integration: Communicating significant risks and decisions; Linking FMEA with control plans; Change triggers lessons and review responsibilities.
• Module 8 Facilitated FMEA Case Workshop: Develop a limited process FMEA; Challenge assumptions and rating consistency; Present action priorities and verification evidence.

Assessment

• 40 single best answer questions, including applied scenarios; one mark per question.
• 60 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied FMEA criteria and templates permitted; internet, messaging and AI tools prohibited.
• Individual applied assessment (30 minutes): Develop a short process FMEA for the supplied operation, including three failure chains, existing controls, justified prioritisation and two improvement actions with owners and verification evidence.
• Assessment criteria: Logical linkage among functions failures effects and causes; Consistent evaluation using the selected methodology; Effective prioritised actions and clear verification arrangements.
• Pass each component separately: 30/40 written marks (75%) and at least 70% on the applied task.
• All mandatory criteria must pass: Do not downgrade a known serious consequence merely to reduce a risk score.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records assessed FMEA skills; it does not authorise regulated product risk acceptance or customer approval.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

222

Total teaching hoursTotal teaching hoursTotal teaching hours

12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.12 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 20 delegates.Maximum 20 delegates.Maximum 20 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Familiarity with the product or process being analysed is required. Basic risk-assessment knowledge is recommended; prior FMEA experience is not mandatory.Familiarity with the product or process being analysed is required. Basic risk-assessment knowledge is recommended; prior FMEA experience is not mandatory.Familiarity with the product or process being analysed is required. Basic risk-assessment knowledge is recommended; prior FMEA experience is not mandatory.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Spend 30 minutes reviewing the supplied process flow, product requirements and defect history, then identify three potential functional failures.Spend 30 minutes reviewing the supplied process flow, product requirements and defect history, then identify three potential functional failures.Spend 30 minutes reviewing the supplied process flow, product requirements and defect history, then identify three potential functional failures.

End of course assessmentEnd of course assessmentEnd of course assessment

40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).40 question written exam (60 minutes) and individual applied task (30 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.75% written and 70% applied, passed separately; full attendance. All mandatory criteria must pass.