• Training & Workshops

Seminar Content

This 2.5 day seminar addresses all of the elements of the Design Failure Mode Effects Analysis (DFMEA) and Design Verification 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.

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 products and/or a 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 product 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 products and processes smoothly

Seminar Outline

• Course Overview and Introductions
• Setting the Stage: APQP Overview
• Chapter 1 – Introduction to Failure Modes and Effects Analysis (FMEA)
• Chapter 2 – Developing an FMEA
  • – The Six Step Approach
• Chapter 3 – Design FMEA Prerequisites
• – The Customer
• – Scope of Analysis
• – Boundary Diagram
• – Breakout Exercise
• – Structural Analysis
• – Breakout Exercise
• – Design Functions - Function Analysis
• – Breakout Exercise
• – Robust Designs
• – P-Diagram
• – Interface Matrix
• Chapter 4 - Developing the Design FMEA
• – DFMEA Structure and Form
• – Header Information
• – Item / Functions and Requirements
• – Breakout Exercise
• – Design Failure Modes – Failure Analysis
• – Breakout Exercise
• – Potential Causes
• – Breakout Exercise
• – Design Controls - Risk Analysis
• – Breakout Exercise
• – Optimization
• – Breakout Exercise
• Chapter 5 – Test Planning and Reporting
• – Design Validation
• – Noise Factors
• – Testing
• Summary