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AIAG-VDA DFMEA (SFMEA and DFMEA) for Practitioners and Facilitators

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Seminar Content

Join Omnex for this important industry approach integrating AIAG and VDA FMEAs. Omnex FMEA experts many who are writers of the FMEA standards have worked extensively with both AIAG and VDA FMEAs formats. They will show you how to manage your existing AIAG or VDA FMEAs and the steps to transition to the AIAG-VDA FMEA approach.

Omnex will share best in class practices to get the most of the AIAG-VDA DFMEA including managing requirements, working with the supply chain, integrating PPMs and also creating a product and process architecture for managing FMEAs. Get the greatest savings by employing Design Reuse and also linking PPM history with AIAG-VDA FMEA. Most of all, get hands on real world experience working with AIAG-VDA DFMEA at our Open Enrollment or on your product onsite.

This 2.5 or 3 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. This class was designed as a “how to” for practitioners and facilitators. This training offers an optional certification exam in addition to an optional one or two days of workshop to develop your own product using AIAG-VDA DFMEA (onsite training only).

The training is a hands on approach to understanding and using the seven steps of the AIAG-VDA FMEA process and to understand 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 in workshops.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the AIAG-VDA FMEA Handbook (1st edition, 2019) issued by AIAG and VDA, APQP Second Edition, and IATF 16949:2016.

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.

Those directly responsible for DFMEA creation or facilitation should attend this course to upgrade their skills to the AIAG VDA DFMEA 1st Edition.

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.

Background in AIAG FMEA 4th edition or VDA FMEA is good, but not required.

Seminar Materials

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

Seminar Goals and Competencies

  • Provide a hands-on approach to the DFMEA process and its relationship to program deliverables and status reporting to provide the competencies needed to introduce new products and processes smoothly.
  • Apply the AIAG-VDA Seven Step Approach to developing SFMEA and DFMEA.
  • Apply the major changes, improvements, and benefits of AIAG-VDA DFMEA
  • Study the changes and differences between AIAG VDA FMEA and AIAG FMEA 4th Edition. How to make the results of both approaches the same?
  • Detail best in class methods of AIAG VDA Design FMEA implementations.
  • Create a Block Diagram, P Diagram, and Interface Diagram
  • Link DFMEA with DVPR and use Prevention Checklists
  • Link SFMEA, DFMEA, Process Flow, PFMEA, and Control Plans
  • Learn how to link DFMEA to failure and warranty history and Cost of Poor Quality (COPQ)
  • Hands on "use of AIAG-VDA FMEA software" and understand role of software in AIAG-VDA FMEA
  • Implementation of the AIAG-VDA and other Supply Chain Standards
  • Use of AIAG-VDA DFMEA Checklist to evaluate DFMEAs completed and to provide consistency when DFMEA is applied.
  • Developing AIAG-VDA DFMEA Transition and Implementation Plan.

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 Seven Step Approach
  • Chapter 3 – Design FMEA Prerequisites
    • – The Customer
    • Step 1: Scope of Analysis
    • – Boundary Diagram
    • Breakout Exercise
    • Step 2: Structural Analysis
    • Breakout Exercise
    • Step 3: 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
    • Step 4: Design Failure Modes – Failure Analysis
    • Breakout Exercise
    • – Potential Causes
    • Breakout Exercise
    • Step 5: Design Controls - Risk Analysis
    • Breakout Exercise
    • Step 6:Optimization
    • Breakout Exercise
    • Step 7:Results Documentation
  • Chapter 5 – Test Planning and Reporting (DVP&R)
    • – Design Validation
    • – Noise Factors
    • – Testings
  • Chapter 6 – Implications of the AIAG-VDA FMEA
    • – What has changed in the AIAG-VDA FMEA vs the 4th Edition
      • - The AIAG-VDA DFMEA will be compared to the AIAG 4th Edition DFMEA using the case study completed during training. (This is relatively easy using software that supports both editions.)
    • – Use of AIAG-VDA DFMEA Checklists to evaluate DFMEAs completed
    • – Changes to the organization and Supply Chain
      • - What are Supply Chain Standards and why they are important
    • – Requirements Management for AIAG-VDA FMEA
    • – Software needs with AIAG-VDA FMEA
      • - AIAG 4th Edition is 2 dimensional and AIAG-VDA FMEA is 3 Dimensional
      • - Reuse of Information and Products/Process Families and Continual Improvement
    • – Linkages of SFMEA, DFMEA, and PFMEA including PPAP
    • – Change Management and FMEA Updates
    • – PPM Defect history, Cost of Poor Quality and FMEA linkages
    • – Getting Started Checklist and Action Plan
  • Summary
  • Certification Exam for AIAG-VDA DFMEA – Optional

Note 1: Breakouts will be conducted using AIAG-VDA FMEA Software

Note 2: Omnex can offer training in IQFMEA, Plato or AQuA Pro for onsite training

Note 3: You can add two additional days for Facilitator Training (onsite training only)

Note 4: You can add one or two days to develop a DFMEA using your product. It will be best if you have a 4th Edition DFMEA for comparison purposes. This training can include your component suppliers.

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