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

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Course Duration: 2 Days - 8 Hours/day

Join Omnex for this important industry approach integrating AIAG and VDA FMEAs. Omnex FMEA experts many who 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. Most of all, get hands on real world experience working with AIAG-VDA PFMEA, Process Flow (Structure Analysis), and Control Plan at our Open Enrollment or at your product onsite.

This 2 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. The training is a hands on approach to understanding

and using the seven steps of the AIAG-VDA PFMEA process. This course is intended to be a dynamic, hands-on offering with approximately half the class time spent in workshops.

This seminar offers an insight to 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 AIAG-VDA Seven Step Approach to developing Process Flow, PFMEA and Control Plans
  • Apply the major changes, improvements, and benefits of AIAG-VDA PFMEA
  • Link SFMEA, DFMEA, Process Flow, PFMEA, and Control Plans
  • Identify special characteristics in manufacturing process design
  • Explain how to prioritize continual improvements
  • 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
  • Learn how to link PFMEA to failure and warranty history and Cost of Poor Quality (COPQ)
  • Study the changes and differences between AIAG VDA FMEA and AIAG FMEA 4th Edition. What are the changes and differences in the two approaches? How to make the results of both approaches the same?
  • 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

  • Chapter 1: Introduction to APQP and PFMEA

o Identify the phases of the APQP development model

o Pinpoint the phase(s) in which key product development deliverables are created

o Apply the concept of concurrent engineering to product development

o Define FMEA

o List the PFMEA objectives and describe its link to DFMEA

  • Chapter 2: PFMEA Planning and Preparation

o Identify the structure and 7 steps in conducting the PFMEA

o Identify and define the 5Ts and describe the importance of teams

o Identify information to enter on the form header

  • Chapter 3: PFMEA Structure Analysis and Function Analysis

o Develop a Process Flow Diagram

o Identify the role of special characteristics as a part of the APQP process

o Breakout Exercise 1: Process Flow Diagram

o Use the Structure Tree for Structure Analysis

o Breakout Exercise 2: Structure Tree

o Identify the process functions and requirements for Function And Requirement Analysis

o Breakout Exercise 3: Function Analysis

  • Chapter 4: PFMEA Failure Analysis and Risk Analysis

o Determine failure modes, mechanisms, causes and effects

o Breakout Exercise 4: Failure Modes

o Breakout Exercise 5: Failure Net

o Develop prevention and detection controls

o Implement various types of controls

o Determine Indices and Action Priority

o Breakout Exercise 6: Process Controls

o Breakout Exercise 7: Risk Evaluation

  • Chapter 5: PFMEA Optimization and Results Documentation

o Define the use of Action Plans in risk mitigation

o Create and implement results documentation

  • Chapter 6: Process Control Plan

o Define the purpose of a Control Plan

o Identify what is needed to populate a generic Control Plan

o Breakout Exercise 8: Create a Control Plan

  • FMEA Summary and Effectively using the AIAG-VDA PFMEA Approach
  • Certification Exam for AIAG-VDA PFMEA – Optional

Those who have direct responsibility for introducing 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 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, workbook, and an AIAG-VDA PFMEA and Control Plan checklist for

evaluating FMEAs and Control Plans and including all team breakout exercises.

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.

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