AIAG-VDA DFMEA (SFMEA and DFMEA) for Practitioners and Facilitators

Course Duration: 2 Days - 8 Hours/day

Omnex is not a VDA or VDA-QMC licensed training provider.

Join Omnex for this important industry approach integrating AIAG and VDA FMEAs. Omnex FMEA experts, many of whom are writers of the FMEA standards, have worked extensively with both AIAG and VDA FMEA formats. They will show you how to manage your existing AIAG or VDA FMEAs and the steps to transition to the AIAG-VDA FMEA approach.

Omnex will share best in class practices to get the most of the AIAG-VDA DFMEA including managing requirements, working with the supply chain, integrating PPMs and also creating a product and process architecture for managing FMEAs. Get the greatest savings by employing Design Reuse and also linking PPM history with AIAG-VDA FMEA. Most of all, get hands-on real world experience working with AIAG-VDA DFMEA at our Open Enrollment or on your product onsite.

This two-day seminar addresses all of the elements of the Design Failure Mode Effects Analysis (DFMEA) and Design Verification Planning process, and defines it as a process within your organization. This class was designed as a “how to” for practitioners and facilitators. This training offers an optional certification exam in addition to an optional one or two days of workshop to develop your own product using AIAG-VDA DFMEA (onsite training only).

The training is a hands on approach to understanding and using the seven steps of the AIAG-VDA FMEA process and to understand how it is managed as a process. This course is intended to be a dynamic, hands-on offering with approximately half the class time spent in workshops.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook 1st Edition (2019) issued by AIAG and VDA, APQP 3rd Edition (2024), and IATF 16949:2016.

Learning Objectives

  • Provide a hands-on approach to the DFMEA process and its relationship to program deliverables and status reporting to provide the competencies needed to introduce new products and processes smoothly
  • Apply the AIAG-VDA Seven Step Approach to developing SFMEA and DFMEA
  • Apply the major changes, improvements, and benefits of AIAG-VDA DFMEA
  • Study the changes and differences between AIAG-VDA FMEA and AIAG FMEA 4th Edition; how to make the results of both approaches the same
  • Detail best-in-class methods of AIAG-VDA Design FMEA implementations
  • Explain how to use the DFMEA with other Safety Analysis tools and how to incorporate Multipoint Faults and Safety / Diagnostic mechanisms
  • Create a Block Diagram, P Diagram, and Interface Diagram
  • Link DFMEA with DVPR and use Prevention Checklists
  • Link SFMEA, DFMEA, Process Flow, PFMEA, and Control Plans
  • Learn how to link DFMEA to failure and warranty history and Cost of Poor Quality (COPQ)
  • Hands-on “use of AIAG-VDA FMEA software” and understand role of software in AIAG-VDA FMEA
  • Implementation of the AIAG-VDA and other Supply Chain Standards
  • Develop AIAG-VDA DFMEA Transition and Implementation Plan

Course Outline

· Chapter 1: Introduction to Advance Product Quality Planning (APQP) and Failure Modes and Effects Analysis (FMEA)

o Phases of the Advance Product Quality Planning (APQP) Development Model

o Concurrent Engineering

o DFMEA Purpose and Objectives, link to PFMEA

· Chapter 2: DFMEA Planning and Preparation

o The Omnex Seven-Step Approach

o Step 1: Project Planning and Preparation / The 5Ts and Importance of Teams

o DFMEA Structure and Form

· Chapter 3: DFMEA Structure Analysis and Function Analysis

o Step 2: Structure Analysis

Ø System FMEA vs. Design FMEA

Ø Boundary Diagrams

Ø Breakout Exercise 1: Boundary Diagram and Scope Statement

Ø Robust Designs: (P) Diagrams and Interface Matrix

Ø Structure Trees

Ø Breakout Exercise 2: Structure Analysis

o Step 3: Function Analysis

Ø Design Functions and Requirements

Ø Flowdown Analysis and Bidirectional Traceability

Ø Breakout Exercise 3: Function Analysis and Requirements Flow-down

· Chapter 4: DFMEA Failure Analysis and Risk Analysis

o Step 4: Failure Analysis

Ø Potential Design Failure Modes

Ø Failure Net Analysis and the Failure Chain

Ø Potential Effects of Failure

Ø Potential Causes of Failure

Ø Single Point Faults and Multipoint Faults

Ø Breakout Exercise 4: Failure Mode, Effects and Cause Analysis

o Step 5: Risk Analysis and Design Controls

Ø Detection and Prevention Controls

Ø Linkage to Special Characteristics

Ø Evaluations (Severity, Occurrence, Detection, and Action Plans)

Ø Breakout Exercise 5: Design Controls, Special Characteristics and Risk Analysis

· Chapter 5: DFMEA Optimization and Results Documentation

o Step 6: Optimization

Ø Recommended Actions and Continual Improvement

o Step 7: Results Documentation

Ø Breakout Exercise 6: Optimization and Results Documentation

· Chapter 6: Test Planning and Reporting (DVP&R)

o Design Validation Plan

o Strategy: Requirements Management and Noise Factors

o Testing Strategies and Methods

o DVP&R Summary

o Breakout Exercise 7: Design Verification Plan and Report (optional)

· [OPTIONAL] Certification Exam for AIAG-VDA DFMEA

Note 1: Breakouts can be conducted using AIAG-VDA FMEA Software.

Note 2: Omnex can offer training in IQFMEA, Plato or AQuA Pro for onsite training.

Note 3: You can add two additional days for Facilitator Training (onsite training only).

Note 4: You can add one or two days to develop a DFMEA using your product. It will be best if you have a 4th Edition DFMEA for comparison purposes. This training can include your component suppliers.

Who Should Attend

Those who have direct responsibility for introducing new products and/or a new manufacturing processes and systems would benefit from this seminar. This includes: program/product managers, quality managers, design engineers, manufacturing engineers, APQP team members and others who have direct responsibility for new product development and improvement.

Those directly responsible for DFMEA creation or facilitation should attend this course to upgrade their skills to the AIAG-VDA DFMEA 1st Edition.

Course Materials

Each participant will receive a seminar manual and a workbook including all team breakout exercises.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.

Note: Omnex does not provide copies of standard(s) during training courses, but clients are encouraged to have their own copy.

Pre-Requisite

No prior knowledge is necessary. However, a mix of students with knowledge of product design & development and/or manufacturing and basic Quality Assurance concepts is preferred.

Background in AIAG FMEA 4th edition or VDA FMEA is good, but not required.

Upcoming Training

AIAG-VDA DFMEA (SFMEA and DFMEA) for Practitioners and Facilitators Program is available in multiple locations globally, including the USA, Canada, Mexico, India, Europe, Thailand, Singapore, Middle East and China.