Quality Dynamics Consultancy Sdn Bhd presents

Mar 24 - 25, 2020 (9am - 5pm) at Holiday Inn Kuala Lumpur Glenmarie

Failure Mode and Effect Analysis (FMEA)

(by Mr. Mohd Pathir Gopalakrishnan )


1.   Learn and describe the purpose of an FMEA and explain the benefits of
      using FMEAs in both design and process engineering situations.
2.   Contribute effectively to an FMEA team.
4.   Customize FMEA rating scales

program content

1.  Introduction to FMEA
      1.  FMEA Purpose & Definition
      2.  Intro to the 7 Main Steps
      3.  The FMEA Worksheet
      4.  Inputs and Outputs to FMEA
      5.  Types of FMEA
              -   Product, Manufacturing Process, Business Process,
                   Equipment, Software, Service, etc.
      6.  Benefits and Purpose of Design FMEA
      7.  Benefits and Purpose of Process FMEA
      8.  History of FMEA
      9.  When to start FMEA
     10.  Pre-Requisites to FMEA
              -   Understanding your Customers Needs
              -   Developing & Evaluating Concepts
              -   Defining the FMEA Project & Scope
              -   Creating an Effective FMEA Team
              -   Gather and review Reference Material
2.  Developing Functions
      1.  Definition of a Function
      2.  The Function Worksheet
      3.  Methods for Function Analysis
              -   Simple Brainstorming
              -   The FAST Diagram
                   (Function Analysis Systems Technique)
              -   Product Function Modeling
              -   Process Functional Modeling
      4.  Organizing the Functions
      5.  Product Example
      6.  Functional Flowcharts
      7.  Process Example
      8.  Class Participant Workshop
3.  Developing Failure Modes
      1.  Failure Mode Definition
      2.  Failure Mode Thought Starters
      3.  Failure Mode Assumptions
      4.  Failure Mode Categories
      5.  DFMEA Example
      6.  PFMEA Example

4.  Determining Effects & Severity Ratings
      1.  Effects Definition
      2.  Cause & Effect Relationship
      3.  Effects Examples
      4.  Severity Rating Definition
      5.  Severity Tables
      6.  Classification Column
      7.  Special Characteristics
      8.  Class Participant Workshop

5.  Determining Cause & Occurrence Ratings
      1.  Cause Definition
      2.  Cause Guidelines
      3.  Assumptions when determining Causes
      4.  Techniques for determining Causes
              -   Fishbone Diagrams
              -   Classic Brainstorming
              -   Fault Tree Analysis
              -   8D
              -   Experience
              -   Experiments
              -   5 Why
      5.  Cause Examples
      6.  Occurrence Rating Definition
      7.  DFMEA Occurrence Table
      8.  PFMEA Occurrence Table
6.  Controls & Detection Rating
      1.  Controls Definition
      2.  Types of Design Controls
      3.  Types of Process Controls
      4.  Examples of Controls
      5.  When Controls are implemented
      6.  Detection Rating Defined
      7.  DFMEA Detection Rating Tables
      8.  PFMEA Detection Rating Tables
      9.  Class Participant Workshop
7.  Assessing Risk
      1.  Risk Defined
      2.  The RPN
    Case Studies


Power Point Presentation, Exercises, Group Discussions & Case Study

who must attend

Managers/engineers/technicians/supervisors who wish to apply FMEA to proactively manage the operation issues or abnormalities to stay competitive in the market by using this systematic, scientific approach.

investment fee / early bird by 11/03/2020

Standard: RM 1,595.00 nett / RM1,495.00 Nett per participant

Group discount: RM1,495.00 Nett / RM1,395.00 Nett per participant for a minimum of 2 participants from the same company

(Fee inclusive of Refreshment, Buffet Lunch, Training Bag, Handouts,  & Certificate of Completion)

registration & payment


Please register online through www.qdc.com.my or call 03-78054587 / 03-78044196. Our phone line operation hours are from 8:30am to 6:00pm from Monday to Friday.

All registration MUST be accompanied with PAYMENT.

Completed registration form with CHEQUES should be made in favor of "Quality Dynamics Consultancy Sdn Bhd" and sent to:

(FEE PAID IS NOT REFUNDABLE but replacement may be made at no additional cost. Quality Dynamics Consultancy Sdn Bhd reserves the right to cancel or reschedule the above course and shall inform participants of the changes)


Mr. Pathir is a Certified Lean 6-Sigma Black Belt Trainer                        

•  B.Sc (Hons) in Science & Technology (Mathematics)
   – University Malaya, Malaysia.

•  Certified Lean 6-Sigma Black Belt ,Certified Six Sigma Green Belt /
    Project Manager - General Electric (USA) Malaysian Appliance Control.

Mr. Pathir was trained in USA and Singapore in Six-Sigma Methodology and Tools (Black Belt) and upon his return to Malaysia, he was sent to China to train the Engineers in Nidec Corporation situated in Dalian.,  manufacturer of Spindle Motors, Mini Fan Motors and other types of motors  on Six Sigma Methodology and Tools.

After graduation Mr. Pathir then joined Thong Fook Plastics (M) Sdn. Bhd.  as a QA Executive heading the QA Dept manufacturing all kind of plastic bags through extrusion process, and later promoted to Technical Executive in-charge of Plastics Injection Moulding Division. He earned Certificate in Plastics Materials and Injection Moulding Process issued by CIAST, Ministry Of Labour. He was trained 6 months in Plastics Injection Moulding at Minolta Precision (M) Sdn Bhd.

His next assignment was Production Manager for Nidec-Copal, a Japanese MNC which is an Optomechatronics company producing Stepper Motors, Trimmer Potentiometer, Clik Motor, PCB Assembly, Fan Motors, Injection Moulding and Metal Stamping. He has led this company to achieve ISO9000 as a Management Representative. He has been trained as a Lead Assessor by QMS and Internal Quality Audit by SIRIM. Pathir was a Production Manager for eight years before joining an American MNC (General Electric USA Malaysian Appliance Components) as Materials & Customer Service Manager.

Pathir’s five years as a Materials & Customer Service Manager have improved productivity of more than US$1,800,000.00 through Six-Sigma activities. He has been certified Green Belt in 2001 but has been a trained Black Belt since 1999. He also received the Phillippe Award 2000 for Distinguished Community Leadership and also completed the Advance Manager’s Course in 2001 conducted by GE.

He is knowledgeable in other areas such as EHS, Ergonomics, ISO 9001:2000. He owns the Chemical Management Framework while in GE. He has been the Chairman of Health and Safety committee for 2 years.

His next portfolio was as a Technical Advisor for the Plastics Division and a Training Consultant for Six Sigma Methodology and Tools for NCPC, an Japanese MNC in the Philippines. He completed many improvements in the Plastics Division through DOE applications for parameters characterization and Optimization. He also trained all Engineers and Managers in NCPC from various departments like Plating, Motors, LED/SMD, Plastics, Metal Stamping, HR and Materials on Six -Sigma Tools (DMAIC).

He also trained NCPC’s customers on DOE application using Minitab 14 Statistical Software and have also taught other customers (Vishay Semiconductor) in Manila (Philippines), Melaka (Malaysia) and in Shanghai (China).

His last assignment was with Exas Philippines Inc. in Cebu and Aikawa Philippines Inc. in Batangas, Philippines as Technical Advisor to the Plastics Dept and a 6-Sigma Training Consultant. His contract expired March 2007 and since then has returned back to Malaysia.

Training and Coaching for Engineers and Managers in Indonesia -  Perawang, Pekan Baru, Jambi, Surabaya and Jakarta in 6-Sigma Green Belt level since May 2008 to end August 2008. These are Pulp and Paper mills in Indonesia.

Pathir also conducted 6-Sigma and other related programs for Proton, Perodua, Petronas, Samsung, NSK Bearing, Konica-Minolta, Nitto Denko, Tesco etc in Malaysia.

He has the capability of identifying improvement opportunities in any manufacturing operations and also possesses problem-solving capabilities. He has conducted many training for both In-House and Public Courses in Kuala Lumpur, Penang and Johor. Other than 6-Sigma Modules, he also teaches Effective Materials Management, Production Planning & Inventory Control, Statistical Forecasting, How to be an Effective QA, The New 7 Seven QC Tools, Cost Reduction Techniques for Manufacturing, 3Q6S, 6-sigma tools for improvements, Pengurusan Stor & Inventori Secara Berkesan, FMEA, MSA, Sampling Techniques, Regression models, DOE,RSM, QCC & 7 QC Tools, SPC, Enviromental Spills (Hazardous Toxic Substances), Simple, Multiple & Logistic Regression, COPQ, 6-Sigma Black Belt, 6-Sigma Green belt, etc.

He also provides excel-based tools for all applications in their respective subjects/topics. This tools works as good as other licensed softwares.

He is fluent in both English and Bahasa Malaysia.