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AIAG & VDA FMEA Course

Failure Mode and Effects Analysis: Failure Prevention in Design and Process

Catalog Area: Quality

Duration: 16 Hrs.

Modality: Online en Vivo, Presencial e In Company

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OBJECTIVE:

Apply the fundamentals of the AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing) to prevent potential design and process failures using the structured 7-step methodology.
Identify functions, failure modes, effects, and causes; evaluate Severity, Occurrence, and Detection (S-O-D); determine Action Priority (AP); and define optimization actions linked to APQP, PFMEA, and Control Plan.
Updated to AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing).

BASIC COURSE INFORMATION:

Competencies to Develop: Failure prevention, risk analysis, 7-step methodology, S-O-D/AP evaluation, cross-functional teamwork, optimization, and DFMEA-PFMEA-Control Plan traceability.

ADDRESSED TO:

Product and Process Engineering, Quality, Manufacturing, APQP/New Product Introductions, Supplier Quality, Supervisors, Managers, and personnel involved in DFMEA/PFMEA.

SYLLABUS

Module 1. AIAG & VDA FMEA Fundamentals and Evolution: Preventive purpose; key differences versus AIAG FMEA 4th Edition, and Action Priority (AP) versus traditional RPN usage.

Module 2. Step 1 – Planning and Preparation: 5Ts, scope, cross-functional team, inputs, Customer Specific Requirements (CSR), and lessons learned.

Module 3. Step 2 – Structure Analysis: Product (DFMEA) and Process (PFMEA) structure, Focus Element, and higher/lower-level elements.

Module 4. Step 3 – Function Analysis: Functions, requirements, characteristics, and performance criteria for design and process.

Module 5. Step 4 – Failure Analysis: Failure Effect (FE), Failure Mode (FM), Failure Cause (FC), and failure chain construction.

Module 6. Step 5 – Risk Analysis: S-O-D evaluation, prevention/detection controls, Action Priority (AP), special characteristics, and technical criteria.

Module 7. Step 6 – Optimization: Actions, owners, target dates, S-O-D/AP re-evaluation, effectiveness verification, and residual risk.

Module 8. Step 7 – Results Documentation and Communication: Action tracking, lessons learned, technical decisions, and FMEA updates.

Module 9. DFMEA → PFMEA → Control Plan Integration: Traceability of requirements, risks, special characteristics, and controls; link to APQP and change management.

Module 10. Practical Workshop and Assessment: Design/process case study analysis, AP determination, and definition of prevention and improvement actions.

BENEFITS

Prevent failures before they reach the customer.
Prioritize actions using Action Priority (AP).
Strengthen consistency across DFMEA, PFMEA, and Control Plan.
Reduce rejections, customer claims, and poor quality costs.
Improve change management and lessons learned.
Technical references: AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing), IATF 16949:2016, AIAG APQP 3rd Edition, AIAG Control Plan 1st Edition, applicable Customer Specific Requirements (CSR).