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AIAG-VDA Product FMEA Overview

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Seminar Content

This two-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


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