New Design/System 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 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
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