Plexus provides training and consulting to organizations from various industry sectors to effectively implement and leverage product development process improvement methodologies such as Advanced Product Quality Planning (APQP) and Production Part Approval Process (PPAP), Control Plans, Failure Mode and Effects Analysis (FMEA), Measurement System Analysis (MSA), and Statistical Process Control (SPC). Since the early 2000’s, Plexus has worked closely with the Automotive Industry Action Group (AIAG) to design, develop, and deploy a robust Core Tools training curriculum in the US and around the world through our global partnerships.

The application of the “Core Tools” is one of the most important mechanisms for an organization who wants to develop and implement an effective product development process to:

  • Meet and exceed industry and customer requirements 
  • Reduce the complexity of product quality planning
  • Ensure engineering design and product specification requirements are met
  • Predict and prevent failures in both the product development and part production processes
  • Ensure process improvements are more effective
  • Assess the quality of your measurement systems, providing a basis for recognizing where improvements can be made

Our Areas of Expertise

AIAG Core Tools Consulting Services

Our mission is to develop a deep understanding of your organization’s internal processes and business needs, and adapt the scope of our consulting efforts to meet your desired business outcomes. The first step is connecting with a Plexus representative and we'll carefully assess your unique needs.



Design & Process
FMEA Development

Cost of Quality
(COQ) Analysis

Outsourced PPAP Review & Disposition


Failure Mode and Effects Analysis (FMEA)

Failure Mode and Effects Analysis (FMEA) is a team-oriented, systematic, qualitative, and analytical method intended to identify, analyze, and mitigate technical risks related to product and manufacturing process design. It supports the five Advanced Product Quality Planning (APQP) phases to improve customer satisfaction by emphasizing defect prevention. When used correctly, a major benefit of the FMEA is being able to mitigate risk while balancing costs leading to organizational stability and growth. The utilization of FMEA is not only limited to the automotive industry. FMEA is also widely used throughout the aerospace, software, food services, medical device, healthcare, consumer appliance, and many other industries.

New AIAG & VDA FMEA Handbook

In June 2019, the AIAG and the German Association of the Automotive Industry (VDA) jointly published the first international guide on Failure Mode and Effects Analysis (FMEA).

Developed with a global team of OEM and Tier 1 supplier subject matter experts, the new AIAG & VDA FMEA Handbook incorporates best practices from both AIAG and VDA methodologies into a harmonized, structured approach. The updated handbook promotes the utility of a process-oriented methodology to help suppliers meet the product performance requirements of global automakers. FMEA is the most commonly used risk analysis method in the automotive industry toolbox, and is emerging within the aerospace industry, helping suppliers predict and prevent failures in both the product development and part production processes. This methodology provides consistent direction and guidance to the entirety of the global manufacturing supply chain, including best practices and examples from AIAG’s and VDA’s previous handbooks and real-world experiences.

Official training courses for the new AIAG & VDA FMEA Handbook are exclusively provided by Plexus International, a certified global provider for AIAG quality products and services.


AIAG & VDA FMEA Handbook eDoc + eLearning Bundle

Purchase the AIAG & VDA FMEA: Essentials for Transitioning eLearning exclusively from and get an electronic version of the new Handbook at a discounted rate.