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AIAG VDA Process FMEA Overview

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Seminar Content

This 2.5 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. It provides an overview of the six steps of the FMEA process and how it is managed as a process. This course is intended to be a dynamic, hands-on offering with approximately half the class time spent on breakout exercises.

This seminar offers an insight to the linkages between various aspects of the PFMEA process. Specifically, the development and linkage of process flows and control plans are addressed. It shows how Process Flows, Control Plans and shop floor documentation can be used to achieve process standardization and improvement.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook (1st edition (draft), 2018) issued by AIAG and VDA.

Who Should Attend

Those who have direct responsibility for introducing new manufacturing processes and systems would benefit from this seminar. This includes: program/product managers, quality managers, design engineers, manufacturing engineers, APQP team members and others who have direct responsibility for new process development and improvement.

Recommended Training and/or Experience

No prior knowledge is necessary. However, a mix of students with knowledge of product design & development and/or manufacturing and basic Quality Assurance concepts is preferred.

Seminar Materials

Each participant will receive a seminar manual and a workbook including all team breakout exercises.

Seminar Goals

  • 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.
  • After this training, the participants will have a clear understanding of the following
    • – Process Flow
    • – Links between Process Flow, PFMEA, Control Plan and Work Instructions
    • – Process FMEA and Control Plan
    • – Aspects of the 1st edition of FMEA handbook (2018) released by AIAG and VDA

Seminar Outline

  • Introduction to Failure Mode and Effects Analysis (FMEA)
  • Developing a PFMEA
  • Process FMEA Prerequisites
    • – Breakout Exercise: Process Flow Diagram
    • – Breakout Exercise: Structure Analysis
    • – Breakout Exercise: Function Analysis
  • Developing the Process FMEA
    • – Breakout Exercise Potential Process Failure Modes
    • – Breakout Exercise: Failure Net
    • – Breakout Exercise: Process Controls
    • – Breakout Exercise: Risk Analysis (Indices and Action Plans)
  • Control Plans
    • – Breakout Exercise: Control Plan


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