FMEA according to the new AIAG & VDA Handbook

Course objectives

The course aims are to teach participants hoe to identify possible failures, critical errors and failures that may occur during the production process and analyze possible causes and consequences at the product development and design stage. Based on the resulting risk priority assessment Action Priority Matrix (AP) to identify process failure detection capabilities and to define effective preventive countermeasures to prevent or prevent failure. Minimizing the occurrence of errors before the start of trial run or mass production.

Course content

• The goals and methodology of FMEA for process, product and design
• Main changes in FMEA comming from the harmonized AIAG & VDA handbook, guidance for implementation of changes
• Basic terms of FMEA (Failure Mode, Failure Cause and Failure Effect)
• 5T during FMEA Planning
• Seven steps approach of harmonized FMEA
  • 1st Step - Planning and Preparation: Project identification, analysis of boundaries, 5T
  • 2nd Step - Structure Analysis: Visualisation of the analysis scope (Structure tree, block diagram, process flow diagram), sub-system and process step identification
  • 3rd Step - Function Analysis: Visualisation of Functions (Parameter diagram, Process flow chart), cascade of risks from producer to internal, external and final user
  • 4th Step - Failure Analysis: Establishment of Failure chain, Potential Failure Effect, Failure Modes, Failure Causes. Using of the Root Cause Analysis tools like Fishbone diagram, Parameter diagram or Failure network diagram
  • 5th Step – Risk Analysis: Assignment of existing and/or planned controls and rating of failures by using of Severity (S), Occurrence (O) and Detection (D) criteria. New Action Priority Matrix (AP) approach for priority setting
  • 6th Step – Optimization: Identification of the actions necessary to reduce risk. Implementation of preventive and corrective actions and evaluation of the effectiveness of actions.
  • 7th Step: Result Documentation: Communication of results and conclusions of the analysis. Communication with management and customers. Documentation of actions taken including confirmation id the effectiveness of the implemented actions and risk assessment after action´s taken.
• Identification of special / safety characteristics
• Implementation of Poka-yoke approach for process mistake proofing
• Four categories of possible root causes (4M: Man, Machine, Material, EnvironMent)
• Changes for Severity, Occurrence and Detection criteria evaluation in accordance with new FMEA Handbook
• Relationship of Control plans to PFMEA
• Why the AIAG and VDA prepared common, harmonized FMEA Handbook?
• When it is necessary to re-evaluate current FMEA analysis? 
• Action Priority Matrix (AP) vs. Risk Priority Number RPN
• New FMEA forms
• Exercise for participants: Solving of the simulated problems by using FMEA methodology
   

Designed for

• Quality Manager
• Quality Engineer
• Process Engineer
• Production Manager
• Project Manager
• Development and Manufacturing Technologist
• Metrologist

Additional information

* UTC +1 time zone (DE, BE, DK, NL, NO, SE, AT, ES, FR, IT, SI, SK, CZ, PL, HU, ...)