Failure Mode and Effects Analysis (FMEA) Based on AIAG-VDA Harmonized Edition

Course Description
The AIAG & VDA FMEA manual is not a revision of the previous AIAG FMEA handbook. It is the product of a collaborative effort between automotive manufacturers and tier one suppliers, along with members of AIAG (Automotive Industry Group) and the VDA (Verband der Automobilindustrie) which is the German association for automotive manufacturers. 

The AIAG & VDA manual is intended to replace both the AIAG 4th edition FMEA handbook and the VDA Product and Process FMEA volume 4 manual. While the manual has technically been completely re-written, there are several aspects that are familiar and tools that we have been using for years prior to this publication. However, there are some significant segments of the FMEA process that have been modified. Key differences include an increased push for prevention controls over detection. 

In addition, the FMEA process has been transformed into a seven-step system that integrates the robustness tools that many FMEA facilitators utilize today into the FMEA standard process. In addition, the RPN has been eliminated and replaced by an “Action Priority” process that includes a set of tables used to define a priority for action to reduce risk regardless of the number of actions identified in the FMEA process. 

This 2-day workshop 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 class was designed as a “how to” for practitioners and facilitators. Training utilizes a hands-on approach to understanding and using the seven steps of the AIAG-VDA PFMEA process. 

In addition, this workshop provides 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, APQP Second Edition, and IATF 16949:2016.

Who Should Attend
This course is designed for core Process FMEA team members, including: process and manufacturing engineers, process validation engineers, quality and reliability engineers, FMEA moderators/facilitators, project managers, auditors, and others with the background and experience with Process FMEA.

Learning Objectives
Through training, participants will learn to:

  • Describe the benefits of a robust technical risk analysis using the PFMEA approach described in the AIAG & VDA FMEA Handbook
  • Apply the 7-Step Approach in the execution of an actual PFMEA
  • Evaluate the consistency of PFMEA application
  • Develop an implementation plan for the AIAG & VDA FMEA
  • Describe the type of information that should be entered in each Control Plan column
  • Utilize information gathered from performing a FMEA to construct a Control Plan
  • Develop control plans for your manufacturing processes

Course Outline

  • Overview of FMEA Foundations based on the new AIAG & VDA FMEA Handbook
  • Introduction of New AIAG VDA FMEA, Scope and Type of FMEAs.
  • New 7 Step Approach in FMEA
  • How to prepare & use Block Diagram, P-Diagram in DFMEA System Analysis
  • How to prepare and use Process Flow Diagram, P-Diagram in PFMEA System Analysis
  • Understanding of Severity, Occurrence & Detection Rankings for DFMEA
  • Understanding of Severity, Occurrence & Detection Rankings for PFMEA
  • Action Priority & Risk Optimization with use of AP table
  • Risk Documentation
  • Importance of Special Characteristics and use of Filter Code in DFMEA & PFMEA
  • DFMEA Examples with Exercise
  • PFMEA Examples with Exercise
  • Allocation of Assignment and submission of developed FMEA prior to appear for the exam
  • Qualification Exam


Course Format
16 hours
Combination lecture and classroom exercises
Available at QSG’s training facilities, on-site at your organization, and virtually

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