Failure Modes & Effects Analysis (FMEA)

Introduction

In an increasingly complex operational environment, many organisational failures are not due to lack of effort but due to risks embedded within everyday processes that go unrecognised until incidents occur. This programme is designed to be highly practical and implementation-focused. Participants will work on real or realistic workplace processes throughout the programme and will leave with an implementation-ready FMEA that can be immediately applied within their departments. This programme emphasises risk-based thinking, sound professional judgement and sustainable application rather than theory-heavy instruction.

Learning Outcomes / Benefits

After completing the course, participants will be able to:

• Apply FMEA immediately at work
• Identify and analyse the effects and causes of failure modes accurately
• Evaluate risks using Severity, Occurrence and Detection ratings
• Prioritise risks using Risk Priority Number (RPN)
• Design and implement effective preventive actions
• Support audits, accreditation and continuous improvement initiatives

Key Content

Module 1: Risk-Based Thinking & Preventive Mindset

Purpose: Shift participants from reactive problem-solving to preventive thinking

Key Topics:

• Why failures occur in well-intentioned systems
• Reactive vs preventive cultures
• Cost of failure: safety, quality, time, reputation
• Where FMEA fits in organisational risk management

Practical Application:
Identify one real process participants want to analyse during the programme

Module 2: Process Mapping & Failure Identification

Purpose: Build a strong foundation for accurate FMEA

Key Topics:

• Breaking down a process into clear steps
• Defining failure modes correctly
• Distinguishing between failure mode, effect and cause
• Common FMEA mistakes and how to avoid them

Practical Application:

• Map an actual workplace process (own department or given case)

Module 3: Risk Evaluation Using S, O & D

Purpose: Ensure credible and consistent risk scoring

Key Topics:

• Severity: assessing impact realistically
• Occurrence: estimating likelihood objectively
• Detection: evaluating control effectiveness
• Rating calibration and team consensus

Practical Application:

• Apply S, O, D ratings to mapped failure modes

Module 4: RPN Analysis & Risk Prioritisation

Purpose: Turn data into decisions

Key Topics:

• Calculating and interpreting RPN
• Identifying critical risks
• Limitations of RPN and practical judgement
• Risk acceptance vs risk treatment

Practical Application:

• Rank risks and select top priorities for action

Module 5: Designing Effective Preventive Actions

Purpose: Move from analysis to meaningful action

Key Topics:

• What makes a strong preventive control
• Linking actions to root causes
• Human factors, system design & poka-yoke thinking
• Ownership, timelines, and success measures

Practical Application:

• Redesign controls and improve weak processes
• Develop an action plan for top risk

Module 6: Implementation, Facilitation & Sustainability

Purpose: Ensure FMEA continues after training

Key Topics:

• Using FMEA as a living document
• Integrating FMEA into audits, KPIs and improvement cycles
• Facilitating FMEA discussions with teams
• Common implementation barriers and solutions

Capstone Exercise:

• Finalise a draft FMEA ready for workplace rollout
• Peer review and facilitator feedback

Target Audience

• Managers, Assistant Managers, Supervisors and Process Owners
• Quality, Risk and Compliance Personnel
• Operations, Technical, Engineering and Support Function Leads
• HR and Service Delivery Leads

Methodology

• Interactive lectures and facilitated discussions
• Guided process mapping and risk analysis workshops
• Realistic, cross-functional case studies
• Facilitator coaching and peer review
• Action planning for workplace implementation