AIAG-VDA Product FMEA Overview Course

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Course Duration: 3 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’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 out 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.

This 2 day (open enrollment) or 3 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 the workshop to develop your own product using AIAG-VDA DFMEA (onsite training only).

The training uses a hands-on approach to understanding and using the seven steps of the AIAG-VDA FMEA process that has been modified and improved by Omnex 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 Second Edition, 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 Omnex-modified DFMEA process (based on the AIAG-VDA Seven Step Approach) to develop SFMEA and DFMEA
  • Detail best in class methods of AIAG-VDA Design FMEA implementations.
  • Explain how to incorporate single and multipoint FMEAs into the same FMEA (Omnex-developed method)
  • Build an FMEA that links with FTA and FMEDA (Omnex-developed method)
  • Create a Boundary/Block Diagram, P Diagram, and Interface Diagram
  • Explain the use of an inter-relationship matrix to identify relationships between functions and design elements
  • 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
  • Utilize Severity, Occurrence and Detection indices and the Action Priority Matrix evaluations to promote Continuous Improvement
  • Use of AIAG-VDA DFMEA Checklist to evaluate DFMEAs completed and to provide consistency when DFMEA is applied.
  • 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

Course Outline

  • Course Overview and Introductions
  • Setting the Stage: APQP Overview
  • Introduction to Failure Mode andEffects Analysis (FMEA)
  • What is an FMEA? (Purpose and Benefits)
  • Maintaining FMEAs
  • Types of FMEAs
  • Developing an FMEA
  • The OmnexSeven Step Approach
  • Design FMEA Prerequisites
  • Step 1:Scope of the Analysis
  • Boundary Diagram
  • Breakout Exercise: Customer and Scope
  • Step 2: Structure Analysis
  • Breakout Exercise: Boundary Diagram
  • Step 3:Design Functions - Function Analysis
  • Breakout Exercise: Function Analysis and Requirements Flowdown
  • Robust Designs
  • P-Diagram
  • Interface Matrix
  • Developing the Design FMEA
  • DFMEA Structure and Form
  • Header Information
  • Item / Functions and Requirements
  • Step 4: Design Failure Modes - Failure Analysis
  • Breakout Exercise: Potential Design Failure Modes
  • Potential Causes
  • Breakout Exercise: Design Causes
  • Step5: Design Controls - Risk Analysis
  • Breakout Exercise: Design Controls
  • Breakout Exercise: Special Characteristics
  • Step 6: Optimization
  • Breakout Exercise: Optimization and Risk Reduction
  • Step 7: Results Documentation
  • Breakout Exercise: Results Documentation
  • Supplemental Analysis Tools(DVP&R)
  • Fault Tree Analysis (FTA)
  • Failure Mode Effects and Diagnostic Analysis (FMEDA)

Breakout Exercise: Thinking Ahead to FTA and FMEDA (instructor-led)

  • Test Planning and Reporting (DVP&R)
  • Design Validation
  • Noise Factors
  • Testing

Breakout Exercise: Design Verification Plan and Report

  • Implications of the AIAG-VDA FMEA
  • What has changed in the AIAG-VDA FMEA vs the 4th Edition?
  • Use of AIAG-VDA DFMEA Checklists to evaluate DFMEAs 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 DFMEA - 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 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

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


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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