FMEA and RCA for Maintenance and Reliability

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Course Overview

Failure modes and effects analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. Root cause analysis (RCA) involves identifying the core issue that sets in motion the cause-and-effect chain causing the problem.

In this course, you will:

  • Learn how to perform an Equipment FMEA
  • Learn how FMEA will improve the reliability of your key assets
  • Understand the importance of performing RCA on all asset breakdowns and learn how to use the resulting information to prevent future failures
  • Understand how knowledge gained from previous FMEAs can be used to develop a maintenance plan for new assets

Who Should Attend?

  • Maintenance and asset managers
  • Plant and facility engineers 
  • Reliability engineers 
  • Managers of preventive or condition-based and predictive maintenance programs 
  • CMMS coordinators or managers 
  • Maintenance leads and technicians

Additional Information

This course, formerly known as, "Failure Mode and Effects Analysis and Root Cause Analysis in Maintenance Management" and "FMEA and RCA for Maintenance and Reliability," is part of the Maintenance and Reliability Management Certificate. Enhance your maintenance skills, while earning a recognized credential. 

Course Outline

The Components of a Reliability Engineering Maintenance Program

  • Reliability-centered maintenance
  • Criticality analysis
  • FMEA
  • Preventive maintenance optimization
  • RCA
  • Reliability engineering
  • Capital project management

RCA

  • Types and strengths of various RCA tools
  • Implementing a sustainable RCA program
  • RCA and continuous improvement
  • RCA fish bones diagram workshop
  • RCA five whys workshop
  • RCA general tools workshop

Basics of Performing an Asset Criticality Analysis

Asset Criticality Analysis Workshop

Implementing a FMEA Program: How to

  • Sell a FMEA program to management, technicians, and production
  • Form and manage the FMEA team
  • Streamline (faster with less effort and high quality results) the FMEA Program
  • Identify functional requirements of production and facility assets
  • Identify the failure modes for each functional requirement
  • Define the effects for each failure mode
  • Define the root causes of each failure mode
  • Identify current controls that will prevent the cause of failure modes or detect a failure mode before an asset breaks down or that will mitigate the effects of a failure mode
  • Brainstorm proactive actions that will reduce the risk or likelihood of an asset/equipment breakdown
    • condition based monitoring or predictive maintenance technologies
    • preventive maintenance programs
    • replacement part inventories
  • Implement proactive actions
  • FMEA workshop

Instructors

Terry Mann

Terry M. Mann is a Senior Lecturer in the Industrial and Systems Engineering (ISyE) Department at UW-Madison and speaks on quality and engineering-related topics, including ISO Standards, Six Sigma, continual improvement, operations management, statistical process control, cellular manufacturing, facilities layout, design of experiments and measurement systems analysis.

Mr. Mann is also an Exemplar Global Associate EMS and Medical Device Auditor, Exemplar Global Principle QMS Auditor, Senior ASQ Certified Quality Auditor, and Partner of Steudel and Mann LLC, and is active in assisting companies in the implementation of ISO 9000-based quality management systems and ISO 14001 environmental management systems through his consulting, training, auditing, and documentation development support.

Mr. Mann holds a B.S. degree in Industrial Engineering (Magna Cum Laude) and an M.S. degree in Manufacturing Systems Engineering from the University of Wisconsin-Madison.

George Williams

George is the founder and CEO of ReliabilityX. He has a master’s degree in reliability engineering from Monash University. He began his career working for his father in maintenance – performing PMs on trucks and trailers – while in high school. George spent 16 years with a major pharmaceutical company, where he began as a technician and worked his way up to global asset management. In 2015, George’s global team won the Uptime Award for Best Maintenance and Reliability Program. He is a certified maintenance and reliability professional and certified reliability leader. In 2016, he was recognized by the Society for Maintenance and Reliability Professionals as Certified Maintenance and Reliability Professional of the Year. He has earned certifications in vibration analysis, infrared thermography, ultrasound, motion amplification, and plant maintenance management. George is a published author and a recognized leader in reliability. He’s been teaching maintenance and reliability classes for UW-Madison Engineering Professional Development since 2010.

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Program Director

Jeff Oelke

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