Course Details

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Learning Objectives

• Describe major changes, improvements, and benefits on the foundations of Process FMEA execution when comparing AIAG FMEA 4th Edition to the new AIAG & VDA FMEA manuals
• Analyze major changes and improvements adopted in the new AIAG & VDA FMEA handbook by completing a detailed comparison between AIAG & VDA FMEA Handbook to the AIAG 4th Edition manual
• Exemplify major changes, improvements, and benefits of Process FMEAs execution when comparing a PFMEA prepared using AIAG FMEA 4th Edition Manual to a PFMEA prepared using the new AIAG & VDA FMEA Handbook
• Identify the major changes and improvements when evaluating the content of a Process FMEA prepared using AIAG FMEA 4th Edition Manual compared to a PFMEA prepared using the new AIAG & VDA FMEA Handbook
• Evaluate the consistency of PFMEA application cases
• Measuring PFMEA effectiveness, efficiency, and linkage to the Cost of Poor Quality (COPQ)
• Develop a Transition Implementation Plan from AIAG FMEA 4th Edition to AIAG & VDA FMEA Handbook

Who Should Attend

Recommended for Core Process FMEA Team to include process/manufacturing engineers, ergonomic engineers, process validation engineers, quality/reliability engineers, project managers, FMEA moderators/facilitators, auditors, and other roles with a background and experience with AIAG Process FMEA.

Course Outline

• Overview of the Major Changes, Improvements, and Benefits of the new AIAG & VDA FMEA Handbook. Detailed introduction chapter emphasizing and clarifying the foundations necessary to develop a robust FMEA.
• Applying 7-Steps approach - a more instrumental, integrated with lessons learned, and error-proofing driven method to develop FMEAs
• PFMEA 1st Step – Planning and Preparation.
• PFMEA 2nd Step – Structure Analysis.
• PFMEA 3rd Step – Function Analysis.
• PFMEA 4th Step – Failure Analysis.
• PFMEA 5th Step – Risk Analysis.
• PFMEA 6th Step – Optimization.
• PFMEA 7th Step – Communication
• Process Flow, PFMEA, Control Plan, and Work Instruction Linkages
• Comparing a PFMEA prepared using AIAG FMEA 4th Edition Manual to a PFMEA prepared using the new AIAG & VDA FMEA Handbook
• PFMEA effectiveness, efficiency, and linkage to the Cost of Poor Quality (COPQ)
• Transition Implementation Plan from AIAG FMEA 4th Edition to AIAG & VDA FMEA Handbook

Delivery Details

Plexus International brings your team together with experienced instructors in an interactive learning environment whether you are joining online or in-person. We have always believed interactivity, application, and group discussion are critical parts of an effective and sustainable learning experience. To ensure that these values hold true, and every participant can build the same caliber of knowledge, each workshop interaction includes the following functionality and features: 

• Trainers & Moderator support: For every session, both trainers and moderators (or on-site staff) will be present and accessible to ensure optimal interaction for each participant, upholding the intimacy of our training model. Participants may interject and raise hands at any time, speak directly to trainers, moderators, and other participants, and share feedback in real-time. 
• Exercises & Break-out Rooms: Throughout the session, participants will be assigned to teams and split into breakouts to privately complete group activities and discussions, then returning to the larger group to present. There will also be quizzes (or polls) throughout to measure knowledge retention during the units. 
• Digital Learning Package or Shipped Materials: Depending on the course, participants may receive a hardcopy of the Participant Training Book and/or receive a digital learning package complete with training handouts, case studies, digital workbooks, and a virtual platform user-guide. 
• Technical Support & Resources:  If this is your first-time training with Plexus International or in a Live Virtual Workshop environment, we have prepared resources and user guides to help you navigate any conferencing technology and will support your teams hands-on in case you need any extra assistance. Join any session 30 minutes early and a moderator or support team member will guide you in experiencing the key functionalities and features used in our training sessions. 

Training in Context

The growing phenomenon of automotive OEMs adopting global platforms with similar subsystems, components, and materials is addressed within the automotive supply chain by the development of product family processes (processes that can produce several part numbers to several customers using common manufacturing processes and shared resources). When a manufacturing quality problem occurs in any “product family process” it brings about the potential risk for shipment of defective parts not only for one, but for several customer products, making technical risk mitigation related to manufacturing quality crucial for the automotive industry. This challenge cannot be addressed without a robust methodology that takes into consideration all potential failure modes to all potential applications.

The new AIAG & VDA FMEA Handbook is a critical update for the industry that addresses this, and other challenges the automotive industry is facing. The concept of robustness exists throughout all sections of the new PFMEA development approach, which is presented in the new AIAG & VDA Handbook. The Handbook contains a structured method for identifying the process steps, their functions, requirements, and potential failure modes.