Optimizing Availability through Reliability and Maintainability
Training Length - 3 Days

7FM Tooling and Equipment FMEA focuses on optimal tooling, dies, molds, and equipment.  Components are consumed by time, energy, unexpected material, unexpected interference, and material nonconformities that can damage tooling and equipment.  The first focus of improvement is to optimize design parameters for reliability.  The second focus is to reduce the time to repair for perishable and high damage risk components as well as tool/die change-over time.  Predictive maintenance ensure that the next mission can be satisfied.  When predictive maintenance signals a potential failure, components are at the end of their life and must be changed.  These expensive components have a reason to be changed.  Preventive maintenance is used for basic cleaning, replacing of fluids, inexpensive perishable components, and maintaining adjustments.


  • Design for Reliability
  • Design for Maintainability
  • Availability as the result of reliability and maintainability
  • Design for assembly of equipment, tooling, dies, and molds
  • Safety
  • Preventive Maintenance
  • Predictive Maintenance

The Analysis

  • Design for Availability: 7FM Tooling and Equipment Failure Mode and Effects Analysis
  • System Level TE FMEA
  • Assembly Level TE FMEA
  • Component Level FMEA
  • Functional block diagram
  • Function definition, technical function definition, function metrics and specifications
  • Testing and selecting of the seven potential failure modes for each function
  • The temporal fault state map for systems, assemblies, and within a component
  • Primary functions and primary failure modes
  • Effects of each primary failure mode
  • The internal failure sequences (internal causes and effects) that lead to the primary failure modes
  • The causes and effects of each failure mode
  • Equipment fault detection, fault detection time, recovery, recovery instruction, and recovery time
  • Safety controls and defect controls
  • Fault prevention, design prevention and increasing reliability and maintainability
  • Prioritizing risks: Severity-harm, mean-time-to-repair, and Poor quality.  Occurrence: mean-time-between-failures.  Detection: equipment fault detection, defect detection, function capability studies, validating full run rates, fault injection testing, function degradation testing, and failure testing
  • Equipment trouble-shooting guidelines
  • Tooling, equipment, dies, and mold set-up instructions
  • Spare part recommended list
  • Replacement component lead times