Failure Mode and Effects Analysis (FMEA) Based on AIAG-VDA Harmonized Edition – Virtual October 2024

Course Summary

This 2-day workshop addresses all of the elements of the Design (DFMEA) and Process Failure Mode Effects Analysis (PFMEA) process consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook (1st edition, 2019) issued by AIAG and VDA, as well as Control Plans in accordance with APQP Second Edition and IATF 16949:2016.

$977.00

October 23, 2024 - October 24, 2024

Event Details

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

Start date: October 23, 2024

End date: October 24, 2024

Start time: 08:30 a.m. EDT

End time: 04:30 p.m. EDT

Venue: Virtual on Zoom

Directions: Training will occur on Zoom. You will be provided with a unique link per registrant. Please plan to login 10 minutes prior to the session start time.

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 Action Group) and 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 2nd edition Product and Process FMEA volume 4 manual. While the manual has technically been completely re-written, there are several aspects that are familiar, and it includes 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. Also 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 Design (DFMEA) and Process Failure Mode Effects Analysis (PFMEA) process consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook (1st edition, 2019) issued by AIAG and VDA. Control Plans in accordance with APQP Second Edition and IATF 16949:2016 are also addressed.

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 Process FMEA background and experience.

Learning Objectives

Through training, participants will learn to:

  • Describe the benefits of a robust technical risk analysis using the FMEA approach described in the AIAG & VDA FMEA Handbook
  • Measure FMEA effectiveness and efficiency and understand the linkage to the Cost of Quality
  • Apply the 7-Step Approach in the execution of an actual DFMEA and PFMEA
  • Link FMEA to Product Development Process / Advanced Product Quality Planning (APQP)
  • Set up an effective Cross Functional Team required for FMEA Development
  • Efficiently select Severity, Occurrence and Detection rankings
  • Define risk and determine levels of risk requiring mitigation
  • Understand and demonstrate the links between Design FMEA and Process FMEA
  • Create and manage action plans derived from FMEA
  • Describe the type of information that should be entered in the Control Plan template
  • Utilize information gathered from performing a FMEA to construct a Control Plan

Course Outline

FMEA Process Overview

  • Introductions and course objectives
  • History 
  • Purpose
  • Benefits
  • Limitations
  • Measuring FMEA Effectiveness & Efficiency
  • Impact of FMEA on the Cost of Quality

 

AIAG-VDA FMEA Handbook

  • Alignment: AIAG & VDA
  • Major Changes 
  • Benefits

 

FMEA Applications

  • FMEA Applications and Scope
  • Two Forms of FMEA (Design and Process)
  • Ideal State
  • Concurrent Engineering and FMEA

 

Design FMEA 7-Step Approach

  • Preparation and Planning
  • Structure Analysis
  • Function Analysis
  • Failure Analysis
  • Risk Analysis
  • Optimization
  • Documentation of Results

 

Process FMEA 7-Step Approach

  • Preparation and Planning
  • Structure Analysis
  • Function Analysis
  • Failure Analysis
  • Risk Analysis
  • Optimization
  • Documentation of Results

 

Control Plans

  • Pre-Launch Control Plan
  • Production Control Plan

Prerequisites

None

Instructors

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