Understanding and Implementing Design and Process FMEA – 4th Edition for Aviation, Space and Defense Organizations

Course Description

This course is designed to establish the use of the AIAG 4th Edition Design and Process FMEA in the context of ASD industry. It also helps participants develop the skills necessary to apply risk reduction and defect prevention practices effectively. 

The program covers the key linkages between Design FMEAs (DFMEAs) and Process FMEAs (PFMEAs) and their connections to other quality assurance documentation. In addition, participants will gain valuable insight and hands-on experience in developing and implementing effective FMEAs. 

Course Details

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Learning Objectives

• Explain the benefits and general framework of FMEA as a risk analysis tool 
• Relate Design and Process FMEAs to APQP 
• 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 Prototype Control Plan 
• Connect the Block Diagram, Design FMEAs, and Prototype Control Plans 
• Utilize information gathered from performing an FMEA and construct a Pre-Launch/Production Control Plan 
• Connect the Process Flow, Process FMEAs, Control Plans and Work Instructions 

Who Should Attend

Recommended for Core Process FMEA Teams, including product engineers, 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  

• Block Diagrams 
• Functional Analysis relationship at the system, subsystem and component levels 
• Developing and implementing Design FMEAs 
• Failure Modes 
• Effects 
• Occurrence 
• Detection 
• Process Controls 
• Risk 
• Managing Improvement Actions – Actions to reduce Severity, Occurrence, and Detection 
• Design FMEAs and Prototype Control Plan Linkages 
• Design FMEA and Process FMEA Linkages 
• Design FMEA Application 

Day 2  

• 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 

Certificate

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