Module 1. Fundamentals and Evolution of AIAG & VDA PFMEA: Purpose of process 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, lessons learned, and responsible reuse of Foundation/Family FMEAs.

Module 3. Step 2 – Structure Analysis: Process Item, Process Step/Station, and Process Work Element; building the structure from the Process Flow Diagram and inter-level relationships.

Module 4. Step 3 – Function Analysis: Functions and requirements for processes, products, and work elements; performance criteria and traceability of special characteristics.

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

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

Module 7. Step 6 – Optimization: Risk reduction actions, prevention, detection, and error proofing; action owners, 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. Flowchart → PFMEA → Control Plan Integration: Coherence of operations, risks, special characteristics, control methods, and work instructions; link to APQP 3rd Edition and change management.

Module 10. Practical Workshop and Assessment: Development/review of an automotive PFMEA, consistency checklist, effectiveness evaluation, and criteria for updating legacy PFMEAs from AIAG FMEA 4th Edition; shop-floor verification where applicable.