AIAG-VDA Process FMEA and Control Plans for Practitioners and Facilitators

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Note:Pricing is dependent on location and may vary.

Course Duration: 2 Days - 8 Hours/day

Omnex is not presently a VDA licensee. If the VDA auditor “card” is required by a customer for their suppliers’ auditors, attendees should confirm with a licensed provider if they can take the official exam after this course.

Join Omnex for this important industry approach integrating AIAG and VDA FMEAs. Omnex’s FMEA experts, many of whom are writers of the FMEA standards, have worked extensively with both AIAG and VDA FMEAs 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 PFMEA including managing requirements, integrating PPMs and Warranty History, and creating a product and process architecture for managing FMEAs. Get the greatest savings by employing Process Reuse and also linking PPM and Warranty History with AIAG-VDA PFMEA.

This 2 day (open enrollment) or 3-day seminar addresses all of the elements of the Process Failure Mode Effects Analysis (PFMEA) and Control Planning process and defines it as a process within your organization. This class was designed as a “how-to” for practitioners and facilitators, utilizing a hands-on approach to understanding and using the seven steps of the AIAG-VDA PFMEA process that has been modified and improved by Omnex. This course is intended to be a dynamic, hands-on offering with approximately half the class time spent in workshops. This training offers an optional certification exam in addition to an optional one or two days of the workshop to develop your own process using AIAG-VDA PFMEA (onsite training only).

This seminar offers an insight into the linkages between various aspects of the PFMEA process. Specifically, the development and linkage of process flows/structure analysis and control plans are addressed. It shows how Process Flows/structure analysis, Control Plans, and shop floor documentation can be used to achieve process standardization and improvement.

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 Second Edition, and IATF 16949:2016.

Learning Objectives

  • Provide a hands-on approach to the FMEA process and its relationship to program deliverables and status reporting to provide the competencies needed to introduce new processes smoothly.
  • Apply the Omnex-modified PFMEA process (based on the AIAG-VDA Seven Step Approach) to develop Process Flow, PFMEA and Control Plans
  • Link SFMEA, DFMEA, Process Flow, PFMEA, and Control Plans
  • Utilize Severity, Occurrence and Detection indices and the Action Priority Matrix evaluations to promote Continuous Improvement
  • Hands on “use of AIAG-VDA FMEA software” and understand role of software in AIAG-VDA FMEA
  • Use of AIAG-VDA PFMEA and Control Plan Checklists to evaluate PFMEAs completed and to develop consistency between PFMEAs and Control Plans in the organization
  • Link PFMEA to failure and warranty history and Cost of Poor Quality (COPQ)

  • Course Overview and Introductions
  • Setting the Stage: APQP Overview
  • Introduction to Failure Mode and Effects Analysis (FMEA)
  • What is an FMEA? (Purpose and Benefits)
  • Maintaining FMEAs
  • Types of FMEAs
  • Developing an FMEA
  • The Omnex Seven Step Approach
  • Process FMEA Prerequisites
  • Step 1: Scope of the Analysis
  • Process Flow Diagram
  • Breakout Exercise: Process Flow Diagram
  • Step 2: Structure Analysis
  • Breakout Exercise: Structure Analysis
  • Step 3: Function Analysis
  • Breakout Exercise: Function Analysis
  • Developing the Process FMEA
  • Process Failure Modes
  • Step 4: Failure Analysis
  • Breakout Exercise: Failure Modes
  • Step 5: Risk Analysis
  • Process Controls
  • Breakout Exercise: Failure Net
  • Indices and Action Plans
  • Breakout Exercise: Process Controls
  • Breakout Exercise: Indices and Action Plans
  • Step 6: Optimization
  • Step 7: Results Documentation
  • Control Plan
  • What is a Control Plan?
  • IATF 16949 Requirements
  • Control Plan Fields
  • Breakout Exercise: Control Plan
  • Implications of the AIAG-VDA FMEA
  • What has changed in the AIAG-VDA FMEA vs the 4th Edition?
  • Use of AIAG-VDA PFMEA Checklists to evaluate PFMEAs completed
  • Changes to the organization and Supply Chain - what are Supply Chain Standards and why they are important?
  • Requirements Management for AIAG-VDA FMEA
  • Software needs with AIAG-VDA FMEA - AIAG 4th Edition is 2-Dimensional and AIAG-VDA FMEA is 3-Dimensional
  • Reuse of Information and Products/Process Families and Continual Improvement
  • Linkages of SFMEA, DFMEA, and PFMEA including PPAP
  • Change Management and FMEA Updates
  • PPM Defect history, Cost of Poor Quality and FMEA linkages
  • Getting Started Checklist and Action Plan
  • Summary
  • Certification Exam for AIAG-VDA PFMEA - Optional

Note 1: Breakouts will 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 PFMEA using your own product. It will be best if you have a 4th Edition PFMEA and Control Plan for comparison purposes. This training can include your component suppliers.

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

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

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

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

Background in AIAG FMEA 4th Edition is good, but not required.

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