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Process Flow, PFMEA and Control Plans

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Seminar Content

This two-day seminar offers insight into, and hands-on experience with the development and linkage of Process Flows, PFMEAs and Control Plans. It shows how Process Flows, PFMEAs, Control Plans and shop floor documentation can be used to achieve process standardization and improvement.

This course is offered in a dynamic and practical way with minimal lecture and more focus on student workshop breakouts and discussion.

Who Should Attend

This seminar is designed for development coordinators, APQP team members, process engineers, quality professionals, PPAP coordinators, and project managers.

Recommended Training and/or Experience

Process, Product or System audit experience is recommended.

Seminar Goals

  • Demonstrate an ability to properly and effectively complete all items in the PFMEA process
    • Demonstrate an ability to properly construct a Process Flow Diagram
    • Identify steps, requirements, failure modes, causes and controls, and properly enter the information in a PFMEA
  • Explain the relationships among a Process Flow Diagram, PFMEA and Control Plan
  • Identify special characteristics in manufacturing process design
  • Explain how to prioritize continual improvements with a focus on the use of Sev, Sev x Occ, and Sev x Occ x Det ratings

Seminar Outline

  • Course Overview and Introductions
  • Introduction to Failure Modes and Effects Analysis (FMEA)
  • Developing an FMEA
  • Process FMEA Prerequisites
    • Process Flow Diagram Breakout Exercise
  • Developing the Process FMEA according to VDA
    • VDA Five-Step FMEA Approach
    • QM-Tools
    • Potential Causes
    • Process Controls
    • Risk Analysis (RPN)
    • PFMEA: conducting and evaluating
  • Control Plan
  • Work Instructions

Seminar Materials

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


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