AIAG & VDA Process FMEA: Transitioning for Practitioners

Transitioning your PFMEA from the AIAG FMEA 4th Edition to the AIAG & VDA FMEA Handbook.

Learn to execute Process FMEA according the new handbook by achieving a deeper understanding of the explicit and subtle changes, along with high impact benefits that will bring your organization’s PFMEA to the next level of manufacturing process design robustness.

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.

By the end of this training you will be able to describe, analyze, exemplify and apply the improvements in the AIAG & VDA FMEA Handbook. Additionally, you will gain the skills necessary to evaluate the consistency of PFMEA application, measure its effectiveness and efficiency within your organization, and develop a Transition Implementation Plan from the AIAG FMEA 4th Edition methodology to the 7-Step approach recommended by the AIAG & VDA FMEA Handbook.

Course Details

Length

2 Days

For training delivered on-site at your organization, a one (1) day add-on Application Coaching Workshop service is available (i.e. facilitated development of a partial FMEA based on the Implementation Plan).


Prerequisites

This training requires the individual to have a working knowledge and experience with AIAG FMEA 4th Edition execution.

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.

Agenda

  • 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