Understanding and Implementing Process FMEA and Control Plans – 4th Edition

AIAG FMEA 4TH EDITION • IN-PERSON WORKSHOP • LIVE VIRTUAL WORKSHOP

Understanding and Implementing Process FMEA and Control Plans – 4th Edition

This course is designed to establish the use of 4th Edition Process FMEAs and to help you learn the skills needed to practice risk reduction and defect prevention.The course covers the linkage between Process Flows, Process FMEAs, Control Plans, and the relation with APQP. This course also provides insight and hands-on experience with how to develop and implement Control Plans for your manufacturing processes.

Enrollment Options

Choose from our available Open Enrollment dates or request a private training session below

Length

2 Days

Prerequisites

Participants should have experience working in quality assurance

Explain the benefits and general framework of FMEA as a risk analysis tool
Relate Process FMEAs to APQP and IATF 16949:2016
Define FMEA customers
Identify functions, potential failure modes and effects
Determine potential causes
Identify current prevention and detection process controls
Identify improvement opportunities to reduce the risk of failure
Utilize information gathered from performing an FMEA and construct a Control Plan
Connect the Process Flow, Process FMEAs, Control Plans and Work Instructions
Relate Control Plans and risk-based thinking
Describe the type of information that should be entered in each control plan column
Use the dominant factor analysis of each manufacturing process to determine the most appropriate process control methodology
Ensure Control Plans consistency with other quality planning methodologies
Review and update Control Plans as living documents
Develop Control Plans for your manufacturing processes

Recommended for Development Coordinators, APQP Team Members, Process Engineers, Quality Professionals, PPAP Coordinators, Project Managers, and other manufacturing roles related to quality assurance.

Day 1

Process Flow Charts
Product and Process Characteristics
Special Characteristics
Developing and Implementing Process FMEAs
- Failure Modes
- Effects
- Occurrence
- Detection
- Process Controls
- Risk
- Managing Improvement Actions – Actions to reduce Severity, Occurrence and Detection ratings in the PFMEA
Process FMEAs and Control Plan Linkages
Integrating APQP Quality Plans: Process Flow, Process FMEAs, Control Plans and Work Instructions
Process FMEA Application

Day 2

Control Plan Foundations: Y=F(X) and Cause-Effect Diagram
Developing and Implementing Control Plans
- Process step description
- Product and Process characteristics description
- Special characteristic symbol
- Control method: specification tolerance, measurement technique, sampling determination, control methods
- Reaction plan development
Control Plan linkages
Control Plan robustness based on most common sources of variation or the dominant factors in determining the quality of the product
Key points for Control Plan review – Control Plans as living documents
Control Plan Application

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