AI-Powered Failure Modes and Effects Analysis (FMEA)

This course provides a comprehensive and practical approach to mastering **Failure Modes and Effects Analysis (FMEA)**, combining foundational theory with modern practices, including the AIAG-VDA Action Priority (AP) and optional AI support. It is designed to help engineers, quality professionals, and team leaders confidently conduct both Design FMEAs (DFMEA) and Process FMEAs (PFMEA), regardless of prior experience. FMEA is a cornerstone of quality and risk management across industries, but many professionals struggle to implement it effectively in day-to-day work. This course bridges the gap between theory and practice through a detailed, real-world case study of a cordless electric glass kettle. You will learn how to define system boundaries, identify failure modes and causes, assess risk, and develop meaningful action plans. Both traditional RPN-based methods and the modern Action Priority (AP) approach from the AIAG-VDA handbook are merged to provide a simple and practical approach. The course is designed to be effective with or without AI assistance. For those looking to enhance their workflow, a custom GPT-based assistant is provided to support brainstorming, clarify terminology, generate potential failure modes, and accelerate documentation. A downloadable template is included to reinforce learning and guide implementation. What You Will Learn - Complete FMEA methodology and terminology, including severity, occurrence, detection, and risk prioritization. - How to conduct DFMEA and PFMEA. - How to use both RPN scoring and AIAG-VDA Action Priority (AP) ratings for more effective risk ranking. - Techniques for defining functions, identifying failure modes, causes, and effects, and linking them to appropriate controls. - How to facilitate cross-functional FMEA sessions and maintain the analysis as a living document. - How to leverage AI tools like ChatGPT to streamline analysis, brainstorming, and documentation. Industry Applications FMEA is widely used in automotive, aerospace, electronics, healthcare, manufacturing, construction, and software development. The methods taught in this course can be applied to both products and processes in any industry where reliability, compliance, and safety are critical. Who Should Enroll Quality managers, quality engineers, design engineers, process engineers, Six Sigma practitioners, reliability professionals, and team leaders. It is also ideal for anyone who has learned FMEA in theory but has not successfully applied it in practice. By the end of the course, you will be able to complete an FMEA independently or with your team, and optionally supported by AI tools. You will have the skills to improve compliance, reduce risk, and implement FMEA effectively in your own work environment.