New Process FMEA and AIAG and VDA harmonized

This seminar integrates the new content of the Yellow Book of the harmonized new version of the DFMEA, which has been jointly developed by AIAG and VDA.

Seminar Content

This two-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. 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.

This seminar offers an insight to the linkages between various aspects of the PFMEA process. Specifically, the development and linkage of process flows and control plans are addressed. It shows how Process Flows, 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, 2018) issued the AIAG and VDA.

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.

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 processes smoothly.

After this training, the participants will have a clear understanding of the following

  • Process flow
  • Links between Process Flow, PFMEA, Control Plan and Work Instructions
  • Process FMEA and Control Plan
  • Aspects of the 1st edition of FMEA handbook (2018) released by AIAG-VDA

Seminar Outline

  • Course Overview and Introductions
  • Chapter 1 – Introduction to Failure Modes and Effects Analysis (FMEA)
  • Chapter 2 – Developing an FMEA
    • The six step approach
  • Chapter 3 – Process FMEA Prerequisites
    • The Customer
    • Scope of Analysis
    • Process Flow Diagram
    • Breakout Exercise
    • Structural Analysis
    • Breakout Exercise
    • Process Functions – Function Analysis
    • Breakout Exercise
  • Chapter 4 – Developing the Process FMEA
    • PFMEA Structure and Form
    • Header Information
    • Item / Functions and Requirements
    • Breakout Exercise
    • Process Failure Modes – Failure Analysis
    • Breakout Exercise
    • Potential Causes
    • Breakout Exercise
    • Process Controls - Risk Analysis
    • Breakout Exercise
    • Optimization
    • Breakout Exercise
  • Chapter 5 – Control Plans
    • What is a Control Plan?
    • IATF 16949 Requirements
    • Control Plan Header Information
    • Control Plan Fields
  • Summary