IATF 16949 TRAINING- SERIES

Understanding Process - FMEA

With VDA-AIAG FMEA –Handbook 1st., edition

Created to develop resources capable of leading/managing a dynamic failures prevention with Design FMEA

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 Why automotive industries has request
FMEA to prevent potential failure
processes and design..?
Failure Mode and Effects Analysis (FMEA) is defined as a regular technique used to
inhibit failure. Such action is conducted through the exploration of potential failure
modes and the reasons can cause such failure. FMEA actions occur within a team
activity by tackling high severity, high occurrence, and high detection rankings that
is determined by the analysis. Only through the preventive process of FMEA we can
assure the product performance is satisfactory and the chance of the product failure
is reduced. The Design FMEA training course will help you explore these steps in
detail and learn how to put them in action to prevent the system failure.

FMEA techniques are considered as a quality improvement tool. One of the reasons
why FMEA has gained interests in recent years is because of automotive industry
and implementing IATF 16949. However, other industries such as aerospace,
pharmaceutical, and electronics can benefit from such practice as a risk analysis tool
and to increase the quality of their products. One of the beauties of this technique is
its simplicity. Quality improvement tools are often made of complicated statistical
analysis. Such simple yet sufficient and effective quality technique can save costs for
the organization

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 State of Art
Potential Failure Process Prevention
New Product Development and APQP. It is not a stand-alone tool but one that
needs to implemented with the New Product Development process with APQP
and then afterwards as a part of a “manage the change” process. Let us not
forget that DFMEAs, DVPR, Process Flow, PFMEA, and Control Plans are living
documents that result in a control strategy in design and manufacturing
environments. When we keep this in mind, then we understand the linkage
between these control and risk prevention methodologies and the Cost of
Quality including PPMs
This 1 day seminar addresses all of the elements of the Process Failure Mode
Effects Analysis (PFMEA) and Control Planning process, and defines it as a
process within your organization. This class was designed as a “how to” for
practitioners and facilitators, utilizing aa hands-on approach to understanding
and using the seven steps of the AIAG VDA PFMEA process and AIAg 4 th .,
edition This seminar offers an insight to the linkages between various aspects
of the PFMEA process. Specifically, the development and linkage of process
flows/structure analysis and control plans are addressed. It shows how Process
Flows/structure analysis, Control Plans and shop floor documentation can be
used to achieve process standardization and improvement.

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 Training Objectives

 Provide a hands-on approach to the FMEA process and its

relationship to program deliverables and status reporting to
provide the competencies needed to introduce new processes
smoothly.

 Link DFMEA, Process Flow, PFMEA, and Control Plans

 Utilize Severity, Occurrence and Detection indices and the Action

Priority Matrix evaluations to promote Continuous Improvement

 Use of AIAG-VDA PFMEA and Control Plan Checklists to evaluate

PFMEAs completed and to develop consistency between PFMEAs
and Control Plans in the organization

 Link PFMEA to failure and warranty history and Cost of Poor

Quality The approaches discussed and employed in this course
are consistent with the intent and guidelines in AIAG-VDA FMEA
Handbook (1st edition, 2019)

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 Audience
PFMEA training is a 1-day course designed for:
• Engineers, and managers involved with manufacturing
• Production and manufacturing team
• Quality assurance & Quality control
• Vendor development engineer
• Product design personnel
• Reliability, testing, and quality team members
• R&D personnel
• Product and process assurance people
• Assembly personnel

We recommend that participants have the following :

Understanding of ISO 9001:2015 and IATF 16949:2016
requirements and/or work experience in implementing IATF
16949:2016 – and management of new product and process
development projects is recommended, Have a basic
understanding of IATF core tools and Understand quality core
tools
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Course Overview and Introductions

Chapter 1 – Introduction to Failure Modes

and Effects Analysis (FMEA)

Chapter 2 – Developing an FMEA

– The Seven Step Approach

Chapter 3 – Process FMEA Prerequisites

The Customer real process & Problem list
references
• Step 1: Scope of the Analysis Process
Flow Diagram Breakout Exercise:
Process Flow Diagram
• Step 2: Structure Analysis Breakout
Exercise: Structure Analysis
• Step 3: Function Analysis Breakout
Exercise: Function Analysis

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Developing the Process FMEA
Process Failure Modes

• Step 4: Failure Analysis

Breakout Exercise: Failure
Modes
• Step 5: Risk Analysis Process
Controls Breakout Exercise:
Failure Net Indices and Action
Plans Breakout Exercise: Process
Controls Breakout Exercise:
Indices and Action Plans
• Step 6: Optimization
• Step 7: Results Documentation

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