COURSE OVERVIEW:

Failure Mode and Effects Analysis (FMEA) is a systematic, proactive method for evaluating a process or design to identify where and how it might fail and to assess the relative impact of different failures. This course focuses on the harmonized AIAG and VDA FMEA handbook, which represents a globalized approach to risk management in the automotive and manufacturing sectors. By shifting from a "detection" mindset to a "prevention" mindset, organizations can significantly reduce the costs associated with warranty claims, recalls, and internal scrap.

The scope of this training covers the comprehensive Seven-Step Approach, which provides a structured pathway for technical risk analysis. Participants will transition from the old RPN (Risk Priority Number) system to the more robust Action Priority (AP) methodology, ensuring that resources are directed toward the most critical risks. The curriculum explores both Design FMEA (DFMEA) and Process FMEA (PFMEA), emphasizing the importance of functional requirements and failure nets in understanding complex system interactions.

Coverage includes the development of clear failures, identifying the failure mode, its effects on the customer, and the underlying root causes. Attendees will learn how to apply the severity, occurrence, and detection tables to objectively score risks. The course also addresses the integration of FMEA into the wider quality management system, ensuring that it remains a living document that evolves with the product lifecycle and incorporates lessons learned from field performance.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Explain the rationale behind the AIAG and VDA FMEA harmonization.
• Apply the Seven-Step Approach to conduct a rigorous risk analysis.
• Define the scope of analysis using Boundary Diagrams and Interface Matrices.
• Analyze functional requirements and visualize them through P-Diagrams.
• Identify potential failure modes and their impacts on the end-user and environment.
• Construct Failure Nets to visualize the relationship between modes, effects, and causes.
• Evaluate risks using the updated Severity, Occurrence, and Detection tables.
• Determine Action Priorities (High, Medium, Low) to guide mitigation efforts.
• Develop effective preventive and detective controls to lower risk levels.
• Document the results of the FMEA in a standardized, professional format.
• Link FMEA outputs to Control Plans and Work Instructions on the shop floor.
• Facilitate FMEA team meetings and manage cross-functional technical debates.

TARGET AUDIENCE:

Design Engineers, Process Engineers, Quality Engineers, Reliability Specialists, Manufacturing Managers, and Project Leaders involved in product realization.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.