Risk-Based Thinking for Machine Tooling Industry Management Personnel


The most important ingredient of effective “risk-based thinking” implementation in a company is a management that believes the Risk Management System is critical to the company’s success and supports it through daily actions and by allocating resources to it. Before one can believe in something, they must understand it. The objective of the class is to provide a reason for management believing in the importance of a strong Risk Management System to the company’s success.

The Machine Tooling Lifecycle for a company that designs and manufactures Machine Tooling contains many sources of risk exposure. The class will begin with a definition of risk and how risk is reduced. The class will then identify the five sources of risk that all companies who design and manufacture products face during the product life cycle and the tools that are available to reduce or eliminate them. The attendees will be taught how the risk management tools work and the key steps required to use each one correctly. The common mistakes people make when using the tools that lead to a reduction in the effectiveness of the tool in managing risk will also be identified.

Machine Tooling companies that provide processing lines face the challenge of applying risk management to many designs in a short period of time. Risk management tools must be applied individually to each of the stations that make up the processing line. This is probably the biggest reason why the Machine Tooling industry has not been effective in applying risk management tools to Machine Tooling. Suggestions for handling this situation will be provided.

The Key role that managing risk in the Product Lifecycle plays in meeting the risk-based thinking requirements of ISO 9001:2015 and IATF 16949 will be explained.

Who Should Attend

All management personnel who manage personnel involved in the Machine Tooling Lifecycle should attend the class.




1 Day


  1. Key Concepts Covered:
    1. Definition of Risk;
    2. Five major sources of Risk;
    3. Definition of Risk Based PLM® (RBPLM) and how it helps a company reduce Risk;
    4. The four major risk reduction tools of RBPLM and their roles (Requirements Risk Assessment (RRA®), Design FMEA (System, Subsystem, Component), Process FMEA and Application FMEA);
    5. Overview of how RRA® is conducted;
    6. Key support tools of a properly conducted RRA®;
    7. Overview of how Design FMEA (System, Subsystem, Component) is conducted;
    8. Key support tools of properly conducted Design FMEA®;
    9. Overview of how Process FMEA is conducted;
    10. Key support tools of a properly conducted Process FMEA;
    11. Overview of how an Application FMEA is conducted;
    12. Key support tools of a properly conducted Application FMEA;
    13. Linkages between the major risk reduction and support tools of RBPLM;
    14. Resources required to implement RBPLM;
    15. Obstacles to implementing RBPLM;
    16. The relationship between ISO 9001:2015 and RBPLM™.

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"Harpco Systems provides some of the most technologically advanced FMEA software tools on the market, buts its their disciplined technique that further separates them from all the rest. Harpco breaks down the barriers and corrects the pitfalls so companies can reap the full benefits of FMEA. Class room training not only properly teaches FMEA, but participants actually build their business's FMEA as they go and are often blown away by how much work got accomplished. Harpco Systems has become known as the Modern FMEA for a reason. Its structured, simplified and sustainable. Thanks Richard for opening our eyes and the FMEA Flip is awesome!"

I have been working with Harpco Systems for 20 yrs and have seen how their products and services continue to improve to meet customer demands. Harpco’s training is first rate and helps develop new ways of thinking about the importance of creating proper specifications early. Separately, I’ve seen firsthand the effectiveness of using their approach in problem solving, helping to advance problems that had reached a stall using traditional methods.

Rich was asked to help us put together a Design Control and Risk Management program for our Immunodiagnostics products. Rich worked with us to build the necessary infrastructure to make the system comprehensive for the level of complexity needed to handle our products. During this time, Rich was not only helpful in putting the system in place, but also educating us on the thought process to evaluate product design and process control. In doing so, Rich provided us with the fundamental concepts to be able to decompose any product or process problem to arrive at an effective solution. He has left a lasting impression on our organization.
We were very fortunate to work with Rich Harpster and his team as we improved our DFMEA process at Calsonic. There is no better teacher, coach, implementer than Rich when it comes to creating a knowledge base for engineers to use in creating part specs to assure that products meet the customer's requirements.
"I would like to thank Harpco Systems for the help, advice and frankly the education in how to design, develop, source and manufacture new to world products. Not only was the Harpco Systems process scrupulously meticulous in making us evaluate, question, define and then justify every single aspect of our product design, project risks and manufacture process, it was done at a pace that saved us months by not following our conventional processes. By cutting out all the waste and focusing our resources on what was truly important Harpco Systems enabled us to get to a state of production readiness months ahead of our projected schedule. This combined with the incredibly detailed, well documented and most importantly correctly linked/associated technical and risk file information prepared us with a watertight project file with no liabilities missed. Harpco Systems has changed the way myself and others approach product design and development for the better."
Jonathan Flood, Engineering Manager