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Understanding Core Tools: PFMEA and Control Plans

Seminar Content

This one-day overview offers insight into, and hands-on experience with, the linkages between various aspects of the APQP process. Specifically, the development and linkage of Process Flows, PFMEAs and Control Plans are addressed. It shows how Process Flows, PFMEAs, 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 APQP 2nd Edition, FMEA 4th Edition, and PPAP 4th Edition manuals issued by GM, Ford and FCA through the AIAG.

Who Should Attend

  • Development Coordinators
  • APQP Team Members
  • Process Engineers
  • Quality Professionals
  • PPAP Coordinators
  • Project Managers

Recommended Training and/or Experience

Participants should possess a working knowledge of quality systems and methodologies, and have some experience in ISO-based quality management systems.

Seminar Materials

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

Seminar Goals

After this training, the participants will have knowledge and understanding of:

  • Process Flow
  • Links between Process Flow, PFMEA, Control Plan and Work Instructions
  • The FMEA as analytical process
  • Process FMEA and Control Plan

Seminar Outline

  • APQP and PFMEA Introduction
    • APQP Phases
    • PFMEA Defined
    • PFMEA as a Living Document
  • APQP Inputs to PFMEA and Process Flow Diagram
    • Phase II Inputs/Deliverables
    • Phase III Deliverables
    • Process Flow Diagram
    • Breakout Exercise 1: Developing a Process Flow Diagram
    • Print Preparation
    • Special Characteristics
    • Phase III Inputs/Deliverables
    • PFMEA Analytical Sequence
  • Developing a Process FMEA
    • Preparing the PFMEA
    • Failure Mode and Effects
    • Controls Prevent / Detect
    • Risk Priority Number
    • Classification Column
    • Breakout Exercises 3-5: Developing a PFMEA
  • Developing a Control Plan
    • What is a Control Plan?
    • Control Plan Header Information
    • Control Plan Fields
    • Breakout Exercise 6: Creating a Control Plan


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