Event Details

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

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

John Gaumond

★★★★★ 5/5

All the participants in your training were also very impressed with you and your training. They each mentioned to the management team how this was the best training they have received and how your energy and enthusiasm kept them excited and motivated. We really appreciate all you and the team have done for us. We will be in touch soon to review and discuss future trainings.

Tepha Inc.

Paul was definitely very knowledgeable, shared much of his experiences and was very personable. He was able to take a topic that could be very dry and made it interesting. The overall thoughts were that both classes were valuable – especially to those with only several years in the industry.

Curtis Schmidt

Hi Barbara and Angelo,

Thank you for the Holiday cheers! We look forward to working with QSG in 2018. We’ve accomplished a lot together as partners and our Training Program has been a great success thanks to you and QSG. Autoliv’s employees are very grateful to QSG for the opportunities to learn new skills and Autoliv appreciates our employees using these new skills to continually improve our Organization.

Hi Angelo,

The training workshops have been very well received and we are very happy with all that have been completed. The upcoming 5S training is full and we already have others interested so we will be looking to add a class. I am also pushing for additional training with all the training events in all areas of our business.

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

Course Summary

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