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AIAG & VDA DFMEA Course (1st Edition, 2nd Printing)

Design Failure Mode and Effects Analysis

Catalog Area: Quality

Duration: 16 Hrs.

Modality: online and Face-to-face modality

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OBJECTIVE:

Develop, review, and maintain robust DFMEAs in accordance with the AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing), applying the structured 7-step methodology.
Analyze structure, functions, and failure chains; evaluate Severity, Occurrence, and Detection (S-O-D); and determine Action Priority (AP) to drive technical design risk reduction.
Strengthen DFMEA integration with APQP, Customer Specific Requirements (CSR), special characteristics, PFMEA, lessons learned, and change management.
Updated to AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing).

BASIC COURSE INFORMATION:

ADDRESSED TO:

Product and Design Engineering, Quality, Reliability, APQP/New Product Introductions, Supplier Quality, Projects, Supervisors, Managers, FMEA facilitators, and Auditors.

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

SYLLABUS

Module 1. Fundamentals and Evolution of AIAG & VDA DFMEA: Purpose of technical risk preventive analysis; 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, Focus Element, inputs, CSR, and responsible reuse of Foundation/Family FMEAs.

Module 3. Step 2 – Structure Analysis: System, subsystem, component, and interfaces; structure tree, boundary/block diagrams, and inter-level relationships.

Module 4. Step 3 – Function Analysis: Functions, requirements, performance criteria, interfaces, and function-requirement networks.

Module 5. Step 4 – Failure Analysis: Failure Effect (FE), Failure Mode (FM), and Failure Cause (FC); failure chains/networks and effects on customer, OEM, and end-user, as applicable.

Module 6. Step 5 – Risk Analysis: S-O-D evaluation, current controls, Action Priority (AP), special characteristics, and Customer Specific Requirements.

Module 7. Step 6 – Optimization: Prevention/detection actions, robust design, action owners, and target dates; S-O-D/AP re-evaluation, effectiveness, and residual risk.

Module 8. Step 7 – Results Documentation and Communication: Risk summary, pending actions, technical decisions, lessons learned, and documentation updates.

Module 9. DFMEA → PFMEA Integration: Traceability of requirements, risks, and special characteristics to PFMEA and Control Plan; link to APQP 3rd Edition and change management.

Module 10. Practical Workshop and Assessment: Development/review of an automotive DFMEA, consistency checklist, effectiveness evaluation, and criteria for updating legacy FMEAs from AIAG FMEA 4th Edition.

BENEFITS

Prioritize design risks using Action Priority (AP).
Improve consistency among requirements, functions, failures, actions, and special characteristics.
Reduce failures, late changes, and poor quality costs.
Strengthen traceability with APQP, PFMEA, change management, and CSR.
Technical references: AIAG & VDA FMEA Handbook (1st Edition, 2nd Printing), IATF 16949:2016, AIAG APQP 3rd Edition, AIAG Control Plan 1st Edition, applicable CSR.