AIAG-VDA Process FMEA and Control Plan Training

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Course Duration: 1 Day - 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 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 1-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 is the same training as the Practitioner course but without the breakout case study or exam.

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; IATF 16949:2016 and APQP, xx Edition.

Learning Objectives

  • 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
  • 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?
  • Link SFMEA, DFMEA, Process Flow, PFMEA, and Control Plans.
  • Learn how to link PFMEA to failure and warranty history and Cost of Poor Quality (COPQ).
  • Discuss AIAG-VDA PFMEA Transition and Implementation Plan
  • After this training, the participants will have an understanding of
  • Process Flow and AIAG-VDA PFMEA Structure Analysis
  • Links between Process Flow, PFMEA, Control Plan and Work Instructions
  • Process FMEA and Control Plan
  • All aspects of the 1st edition of FMEA handbook (2019) released by AIAG and VDA

Course Outline

  • Chapter 1: Introduction to Failure Mode and Effects Analysis (FMEA)
  • What is an FMEA?
  • Maintaining FMEAs
  • Types of FMEAs
  • Chapter 2: Developing a PFMEA
  • The FMEA Team
  • Basic Structure of an FMEA
  • Conducting an FMEA
  • Chapter 3: Process FMEA Prerequisites
  • Requirements
  • Scope of the Analysis – Step 1
  • Process Flow Diagram
  • Function Analysis – Step 3
  • Process Failure Modes
  • Failure Analysis – Step 4
  • Risk Analysis – Step 5
  • Process Controls
  • Indices and Action Plans
  • Optimization – Step 6
  • Step 7: Results Documentation
  • Chapter 4 – Process Control Plans
  • What is a Control Plan?
  • IATF 16949 Requirements
  • Control Plan Header Information
  • Control Plan Fields
  • Chapter 6 – Implications of the AIAG-VDA FMEA
  • o What has changed in the AIAG-VDA FMEA vs the 4th Edition
  • The AIAG-VDA PFMEA will be compared to the AIAG 4th Edition PFMEA
  • o Changes to the organization and Supply Chain
  • What are Supply Chain Standards and why they are important
  • Requirements Management for AIAG-VDA FMEA
  • o Software needs with AIAG-VDA FMEA
  • 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

Note 1: Omnex can offer training in IQFMEA, Plato, or AQuA Pro for onsite training

Note 2: You can add one or two days to develop a PFMEA using your product. It will be best if you have a 4th Edition PFMEA and Control Plan for comparison purposes.

Who Should Attend

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.

Course Materials

Each participant will receive a seminar manual.

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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