New Product FMEA and AIAG and VDA harmonized

Seminar Content

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. It provides an overview of the six steps of the FMEA process and 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 on breakout exercises.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook (1st edition, 2018) issued the AIAG and VDA.

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.

Recommended Training and/or Experience

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.

Seminar Materials

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

Seminar Goals

  • 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 products and processes smoothly

Seminar Outline

  • Course Overview and Introductions
  • Setting the Stage: APQP Overview
  • Chapter 1 – Introduction to Failure Modes and Effects Analysis (FMEA)
  • Chapter 2 – Developing an FMEA
    • The six step approach
  • Chapter 3 – Design FMEA Prerequisites
    • The Customer
    • Scope of Analysis
    • Boundary Diagram
    • Breakout Exercise
    • Structural Analysis
    • Breakout Exercise
    • Design Functions – Function Analysis
    • Breakout Exercise
    • Robust Designs
    • P-Diagram
    • Interface Matrix
  • Chapter 4 – Developing the Design FMEA
    • DFMEA Structure and Form
    • Header Information
    • Item / Functions and Requirements
    • Breakout Exercise
    • Design Failure Modes – Failure Analysis
    • Breakout Exercise
    • Potential Causes
    • Breakout Exercise
    • Design Controls - Risk Analysis
    • Breakout Exercise
    • Optimization
    • Breakout Exercise
  • Chapter 5 – Test Planning and Reporting
    • Design Validation
    • Noise Factors
    • Testing
  • Summary