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AIAG-VDA FMEA for Managers and Implementers – Implementation Training

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Seminar Content

Join Omnex for this important automotive industry initiative integrating AIAG and VDA FMEAs. Omnex has worked with 1000s of organizations for over 40 years implementing FMEA in an APQP and New Product Development environment. AIAG-VDA FMEA needs to be understood in the context and its role in 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.

Omnex FMEA experts many who are writers of the FMEA and Core Tools standards have worked extensively with both AIAG and VDA FMEA formats. Also, Omnex has extensive background in implementing not only FMEAs but APQP, Core Tools and IATF 16949. So, number one, it is a part of an overall process of APQP, IATF 16949 and Core Tools, Second, it is important to understand AIAG-VDA FMEA as an approach that links the supply chain through the structure analysis, and failure analysis. Third, it is also the start of many standards that we will see as the industry transitions from Gas and Diesel vehicles to Electric Vehicles and Autonomous Cars. AIAG-VDA FMEA enhances and supports ISO 26262 with FMEAs and the MSR.

This 2 day seminar will share best in class practices to get the most of the AIAG-VDA FMEA including managing requirements, working with the supply chain, integrating PPMs and also creating a product and process architecture for managing FMEAs. This seminar will help you to get the greatest savings by employing Design and Process Reuse and also linking PPM and warranty history with AIAG-VDA FMEA.

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, and others who have direct responsibility for new product development and improvement.

Managers and those responsible for New Product Development processes and FMEAs in their organization or with the supply chain should attend this seminar to make the needed changes in the management system. Omnex recommends an implementation leader to drive AIAG VDA FMEA implementation within the organization. The training has been tailored for the Manager and Implementation leaders who need to drive the change within the organization.

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 Transition workbook and implementation plan.

Seminar Goals and Competencies

  • Understand the AIAG-VDA FMEA process and its relationship to program deliverables and status reporting to provide the competencies needed to introduce new products and processes smoothly.
  • Understanding the AIAG-VDA Seven Step Approach to developing FMEA and the differences to AIAG-VDA 4th Edition
  • Understand the major changes, improvements, and benefits of AIAG-VDA FMEA
  • Understand the “use of AIAG-VDA FMEA software” and the role of software in AIAG-VDA FMEA
  • Implementation Steps of the AIAG-VDA and other Supply Chain Standards
  • Developing AIAG-VDA DFMEA and also AIAG DFMEA 4th Edition and transitioning approach internally
  • Use of AIAG-VDA FMEA Transition and Implementation Checklist and complete an Action Plan
  • Understand steps needed for developing in house competencies and linkages needed with Design, Customer, and Supply Chain

Note: Omnex believes that AIAG 4th Edition FMEA and AIAG-VDA FMEA formats will continue in the industry for some time. It is purposeful that we have not titled this class as a Transition Class. We believe FMEA facilitators and teams should understand the Pros and Cons of each method and use the best method under the circumstance. Properly done, both outputs can be the same. Getting the same output in AIAG 4th edition and AIAG-VDA FMEA methods requires true understanding of best in class methods.

Omnex trainers and facilitators have had the opportunity to conduct both formats of FMEAs using various software packages. Join us to understand the right way to implement and how to best implement AIAG-VDA FMEA.

Seminar Outline

Day 1

  • Understand the Seven Step Process for AIAG-VDA DFMEA and AIAG-VDA PFMEA
  • Chapter 1: Background to AIAG and VDA
    • – Comparison between AIAG-VDA FMEA and AIAG 4th Edition.
  • Chapter 2: Comparing AIAG 4th edition and AIAG-VDA FMEA first edition Steps
  • Chapter 3: AIAG-VDA FMEA 7 Steps – DFMEA
    • o Step 1: Scope of Analysis
    • o Step 2: Structural Analysis
    • o Step 3: Design Functions – Function Analysis
    • o Step 4: Design Failure Modes – Failure Analysis
    • o Step 5: Design Controls - Risk Analysis
    • o Step 6: Optimization
    • o Step 7: Results Documentation
  • Chapter 4: AIAG-VDA FMEA 7 Steps – PFMEA
    • o Step 1: Scope of the Analysis
    • o Step 2: Structure Analysis
    • o Step 3: Function Analysis
    • o Step 4: Failure Analysis
    • o Step 5: Risk Analysis
    • o Step 6: Optimization
    • o Step 7: Results Documentation

Day 2 Implementing AIAG VDA FMEA in the New Product Development Process with APQP

  • Changes to the organization and Supply Chain
    • – Supply Chain Standards and why they are important
  • AIAG-VDA DFMEA and PFMEA and Changes and implications to the New Product Development and APQP process
    • – Cross-functional team members for successful AIAG-VDA FMEA – Design and Manufacturing
  • Design and Process Reuse and the product and process architecture
  • Linkages of SFMEA, DFMEA, and PFMEA including PPAP
  • Requirements Management for AIAG-VDA FMEA
  • Software needs for AIAG-VDA FMEA
  • Changes to the Purchasing, Supplier Development and Purchase Order requirements
    • – Developing Internal and Supplier Competencies
  • How to use the AIAG-VDA FMEA to improve Cost of Quality and including External and Internal PPM
    • – PPM Defect history, Cost of Poor Quality and FMEA linkages
  • Change Management and FMEA Updates
  • Getting Started Transition Checklist and Action Plan
  • Summary

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