INTRODUCTION FOR AIAG VDA FMEA AND CONTROL PLAN

Failure Mode Effect Analysis (FMEA) is an analytical technique used primarily by a  Engineer/Team as a means to ensure that, to the extent possible, potential failure modes and their associated causes/mechanisms have been considered and addressed. End items, along with every related system, subassembly, and component, should be evaluated. In its most rigorous form, an FMEA is a summary of the team’s thoughts (including an analysis of items that could go wrong based on experience) as a component, subsystem, or system is designed. This systematic approach parallels, formalizes, and documents the mental disciplines that an engineer normally goes through in any design process. The purpose of this Control Plan methodology is to aid in the manufacture of quality products according to customer requirements. It does this by providing a structured approach for the design, selection and implementation of value added control methods for the total system. Control Plan provides a written summary description of the systems used in minimizing process and product variation.

COURSE OBJECTIVES

At the end of this course, participants will be able to :

• Understand what is Project Overview.
• Understand the Seven Step Process.
• Understand how to fill up the New Form Sheet.
• Rank correctly Severity, Occurrence and Detection Tables.
• Corrective Action based on Action Prioritization.
• Prepare an effective Process FMEA.
• Differiantiate between product and process characteristics.
• Correct specification and tolerances.
• Correct measurement techniques.
• Prepare an effective Control Plan.

TARGETED AUDIENCE

Managers, Engineers, Supervisors, Leaders,  and staff involved with FMEA and Control Plan

COURSE CONTENT

Day 1

Module 1

• Why AIAG-VDA FMEA 5^th Edition?
• Project Team Objective.
• FMEA Methodology Changes.
• Development Status.

Module 2

• The Seven Step Process.
• 1^st Step : Scope Definition.
• 2^nd Step : Structure Analysis.
• 3^rd Step : Function Analysis.
• 4^th Step : Failure Analysis.
• 5^th Step : Risk Analysis.
• 6^th Step : Optimization.
• 7th Step : Results Documentation.

Module 3

• Change Points From Current AIAG.
• FMEA Tool Usage.
• The FMEA Report View.
• The FMEA Spreadsheet.
• 6^th Step Process And Spreadsheet.
• FMEA process sequence.

Module 4

• Fill-In-The-Blanks Method.
• Step Analysis Method.
• How To Complete A FMEA.
• Design FMEA.
• Process FMEA.

Module 5

• How to rank Severity effectively. 5^th Edition?
• How to rank Occurrence effectively. 5^th Edition?
• How to rank Detection effectively. 5^th Edition?
• How to classify Action Priority?

Module 6

• AP Table – Determining Action Priorities.
• Current Situation.
• New Action Priority.

Module 7

• FMEA key elements.
• Timeliness.
• Teamwork.
• Documentation.
• Requirements for success.
• Potential roadblocks.

Day 2

Module 8   

• Introduction to Control Plan.
• Types of Control Plan.
• Control Plan number.
• Part number latest change level.
• Part name and description.

Module 9

• Supplier/Plant.
• Supplier code.
• Key contact.
• Core team.
• Supplier/Plant approval date.

Module 10

• Original date.
• Revision date.
• Customer engineering approval date.
• Customer quality approval date.
• Other approval date.

Module 11

• Part/process number.
• Process name/operation description.
• Machine, equipment, jigs, tools for manufacturing.
• Product and process characteristics.
• Special characteristics classification.
• Product/process specification and tolerance.

Module 12

• Evaluation/measurement technique.
• Sample size/frequency.
• Control method.
• Reaction plan.
• Workshop on how to prepare an effective Control Plan.