AS9145 Process FMEA: Understanding and Implementing with Control Plans

Course Description

This course is designed to establish the use of the AIAG 4th Edition Process FMEA methodology to meet the AS9145 requirements related to PFMEAs. It also helps participants develop the skills necessary to apply risk reduction and defect prevention practices effectively.

The program covers the linkage between Process Flows, Process FMEAs, and Control Plans, as well as their relationship to APQP. In addition, participants will gain valuable insight and hands-on experience in developing and implementing Control Plans for their manufacturing processes.

Course Details

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Learning Objectives

• Explain the benefits and general framework of FMEA as a risk analysis tool
• Relate Process FMEAs to APQP and AS9145
• Define FMEA customers
• Identify functions, potential failure modes and effects
• Determine potential causes
• Identify current prevention and detection process controls
• Identify improvement opportunities to reduce the risk of failure
• Utilize information gathered from performing an FMEA and construct a Control Plan
• Connect the Process Flow, Process FMEAs, Control Plans and Work Instructions
• Relate Control Plans and risk-based thinking
• Describe the type of information that should be entered in each control plan column
• Use the dominant factor analysis of each manufacturing process to determine the most appropriate process control methodology
• Ensure Control Plans consistency with other quality planning methodologies
• Review and update Control Plans as living documents
• Develop Control Plans for your manufacturing processes

Who Should Attend

Recommended for Core Process FMEA Teams, including process and manufacturing engineers, ergonomic engineers, process validation engineers, quality and reliability engineers, project managers, FMEA moderators or facilitators, auditors, and other professionals with limited working knowledge or experience with the AIAG Process FMEA methodology

Agenda

Day 1  

• Process Flow Charts 
• Product and Process Characteristics 
• Special Characteristics 
• Developing and Implementing Process FMEAs 
• Failure Modes 
• Effects 
• Occurrence 
• Detection 
• Process Controls 
• Risk 
• Managing Improvement Actions – Actions to reduce Severity, Occurrence and Detection ratings in the PFMEA 
• Process FMEAs and Control Plan Linkages 
• Integrating APQP Quality Plans: Process Flow, Process FMEAs, Control Plans and Work Instructions 
• Process FMEA Application 

Day 2  

• Control Plan Foundations: Y=F(X) and Cause-Effect Diagram 
• Developing and Implementing Control Plans 
• Process step description 
• Product and Process characteristics description 
• Special characteristic symbol 
• Control method: specification tolerance, measurement technique, sampling determination, control methods 
• Reaction plan development 

Certificate

Completion of the course affords a Plexus International Certificate of completion.