OPS 010 – AIAG – VDA Failure Mode Effects Analysis (FMEA)

OPS 010 – AIAG – VDA Failure Mode Effects Analysis (FMEA)

Category:
In-House Programs/ Logistic & Quality/ Operation/Process/
8 Discipline Problem Solving

Duration: 2 days
Lectures: InHouse
Certificate of Completion

INTRODUCTION

FMEA is a reliability engineering technique based on the concept of predicting and solving problems before they can occur, thus saving considerable amounts of time, effort and money.

Developed with a global team of OEM and Tier 1 supplier subject matter experts, the new AIAG & VDA FMEA concept incorporates best practices from both AIAG and VDA methodologies into a harmonized, structured approach.

In addition to making it easier for suppliers to meet their customers’ needs during the FMEA development process, the training features major changes such as a new process for FMEA development – the 7-Step Approach – and a new chapter on Supplemental FMEA for Monitoring and System Response (FMEA-MSR). Additional important changes include the following:

  • Totally revised Severity, Occurrence and Detection Tables.
  • The Action Priority (AP) methodology and Tables to replace RPN.
  • New Form Sheets (spreadsheet users) and Software Report Views (software users).
  • Change point highlights from both the AIAG 4th edition FMEA Manual and the VDA Volume 4 FMEA Manual.

Objectives

The objective of this FMEA training is to teach the participants to recognize and evaluate the potential failure of a process/product and the effects of that failure. Also to identify actions that could eliminate or reduce the chance of occurring.

How will you benefit :

By the end of this program, the participants will be able to :

  • Increase customer satisfaction
  • Prevent problems
  • Improve product/process reliability and quality
  • Document risks and actions are taken to reduce risks
  • Understand the process of identifying categorizing and solving problems or resolving concerns

Who Should Attend?

Company personnel who are responsible in managing and support development of AIAG-VDA FMEA in a systematic and effective manner.

Methodology

This programme involves a wide range of learning approaches, including self – assessment, case studies, small group activities and discussions, interactive lectures, experimental learning group assignments and exercises and presentation and critique.

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Day 1

  • Concepts
  • Consequences of error
  • What is an FMEA
  • Brief history of FMEA
  • FMEA – MSR
  • Purpose
  • Scope
  • Benefits
  • FMEA Limitations
  • Integration of FMEA
  • FMEA Norms
  • Application of FMEA
  • Transition Strategy
  • Foundation and Family FMEAs
  • Design FMEA
  • Process FMEA
  • Collaboration between FMEAs
  • Project Planning
  • FMEA – MSR

  • Introduction
  • System level
  • Sub-system level
  • Component level
  • System – example
  • Development of a DFMEA

-Purpose

-PFMEA Project Identification and Boundaries

-PFMEA Project Plan

-Identification of baseline PFMEA

-Process FMEA Header

  • Purpose
  • Process Flow Diagram
  • Structure Tree
  • Collaboration between customer and supplier engineering teams
  • Basis for Function Analysis

  • Purpose
  • Function
  • Function Analysis
  • Requirements
  • Visualization of functional relationships
  • Collaboration between Engineering Teams( Systems, Safety and Components)
  • Basis for Failure Analysis

Day 2

  • Purpose
  • Failure
  • Failure Chain
  • Failure Effects
  • Failure Mode
  • Failure Cause
  • Failure Analysis
  • Relationship between DFMEA and PFMEA
  • Failure Analysis Documentation
  • Collaboration between customer and supplier
  • Basis for Risk Analysis

  • Purpose
  • Current Prevention Controls
  • Current Detection Controls
  • Current Prevention and Detection Controls
  • Evaluations
  • Severity
  • Occurrence
  • Detection
  • Action Priority
  • Collaboration between customer and supplier
  • Basis for Optimization

  •  Purpose
  •  Assignment of responsibilities
  •  Status of the actions
  •  Assessment of the Action Effectiveness
  •  Continual Improvement
  •  Collaboration between FMEA team, Management, Customers and Suppliers regarding Potential Failures

  • Purpose
  • FMEA Report

About Instructors