This course covers FMEA and Control Plan requirements for AS13100 and AESQ Reference Manual RM13004 - Defect Prevention Quality Tools to support APQP and PPAP. This course outlines the competitive advantages of effective Design and Process FMEA's along with the benefits of value-added controls within the control plan.

FMEA is used to support the introduction of new products and processes as well as supporting changes to existing products and processes.

This course is designed for Process Design Practitioners, Process Improvement Teams, Implementation Teams, Internal Auditors and others involved in the implementation or auditing of Process Failure Modes and Effects Analysis and Control Plans. It supports the goal of zero defects, defect prevention and the reduction of variation and waste.  Companies that apply DFMEA, PFMEA and Control Plans will see improved product conformity, better delivery performance and reduced cost of non-quality.

Delegates will become competent in understanding the requirements of DFMEA and creating and analysing Process FMEA's / Control Plans at "Practitioner" level and will develop the capability to apply the methods to implement Failure Mode and Effect Analysis and Control Plans within their organisation. 

General FMEA

• System of defect prevention tools
• Purpose and history of FMEA
• Introduction to scope of AESQ RM13004
• Risk and types of risk management
• FMEA considerations and application
• Cross functional teams
• Define the customer FMEA steps and recommend actions
• FMEA pitfalls
• FMEA types

Design FMEA

• Purpose and history of FMEA
• Design FMEA thinking
• Start points - boundary diagram
• Function, failure modes, effects
• Classification, causes and prevention
• Key characteristics and critical characteristics
• Severity, occurrence, detection and RPN
• Detection and mistake proofing
• Recommend actions and review

Process FMEA

• AESQ RM13004 Requirements for PFMEA
• Process FMEA start points
• Process flow diagram scope and levels of detail
• PFMEA essentials
• PFMEA operation, function, failure mode and effect
• Causes, prevention, value added prevention
• Process mistake proofing
• PFMEA severity, occurrence, detection and RPN
• Recommended actions and review
• Different PFMEA types - e.g. assembly
• Different approaches to creating and maintaining
• PFMEA Part specific
• PFMEA and data duplication
• Creating a reference PFMEA
• Creating a part specific PFMEA - finite failure modes
• PFMEA Review

Control Plan

• Purpose, overview, AESQ RM13004 requirements
• Control plan phases and linkages
• Process flow diagram and the control plan
• PFMEA prevention and detection overview and controls
• Control plan structure and depth
• Control plan development approach
• Product and process characteristics
• Classification, requirements, evaluation, and sample size
• Reaction planning and control plan review

Upon completion of the course, you will receive an Industry Forum AS13100_RM13004 Defect Prevention Quality Tools to Support APQP & PPAP (Including FMEA and Control Plan) Certificate.