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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
  • Aspects of the 4th edition of FMEA released by the AIAG

Seminar Outline

  • Process Flow Charts
  • Product and Process Characteristics
  • Special Characteristics
  • FMEA Development and Engineering Analysis
    • Team
    • Inputs
    • Outputs
  • Process FMEA
    • Failure Modes
    • Effects
    • Occurrence
    • Detection
    • Process Controls
    • Risk
    • Managing Improvement Actions
  • Evaluating PFMEA
  • Control Plans
    • IATF 16949 Requirements
    • Linkages
    • Control Methods
    • Reaction Plans
  • Standardization


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