FMEA (AIAG and VDA standards) – based on proposed changes

CONTENTS:

• FMEA as a risk management tool – what’s the point in improving structures and processes.
• „Failure Mode” – different approaches to defining nonconformities.
• „Effect Analysis” – customer groups for impact analysis.
• FMEA analyzes in various phases of the project: design, trial series, serial production (APQP and MLA).
• 8D vs. FMEA – necessary common points (monitoring the compatibility of documentation).
• Effectiveness of FMEA – FMEA analysis and quality cost accounting.

CONTENTS:

• Design and process FMEA – outline of the course of the analysis.
• 7 steps of FMEA analysis according to AIAG&VDA requirements.
• Relationship between FMEA and related risk assessment methods.
• Forms for FMEA – an overview of possible options.
• Risk assessments: AP, SOD, RPN, risk matrix.

EXERCISES:

• Analysis of FMEA results – risk assessment with multiple indicators.
• Defining the level of risk with the use of AP, RPN and risk matrix.
• Process and product characteristics in FMEA – case study

• STEP 1. Defining the FMEA range:

• legal aspects and protection of know-how,
• responsibility of the board,
• FMEA for a “family” of products (generic),
• „5T” a new approach to FMEA planning.

• STEP 2. PFMEA: Process structure analysis:

• defining process steps and work items (4M+),
• structure visualization.

• STEP 2. DFMEA: Product structure analysis:

• defining the structure: system-subsystem-assemblies-components,
• boundary diagram (BD), PEIM,
• visualization of the product structure.

• STEP 3. Function analysis:

• functions at the customer level – expectations analysis,
• functions as expectations in a process or in design,
• defining a function as a source to describe the causes.

• STEP 4. Error net analysis:

• defining nonconformities,
• looking for causes,
• determining the effects of non-compliance for all customer groups

EXERCISES:

• Building structures: black, green and red.
• Analysis of drawings in terms of looking for functions.
• Workshops with BD and parameter diagram (P-D).

• STEP 5. Risk analysis:

• new and “old” rating tables S, O, D – comparison,
• prevention and detection and their impact on the value of risk assessment,
• Action Priority (AP) – successor of the RPN index (determination and conduct in the field of improvement),
• actions when AP=H and AP=M – when no action is required.

• STEP 6. Optimization:

• changes in the documentation of planned activities, suggested statuses,
• methods of assessing the effectiveness of activities,
• describing the expected level of risk.

• STEP 7. Reporting:

• FMEA report – new mandatory document,
• FMEA revisions – when and how to document,
• sharing FMEA outside the organization – new guidelines.
• Changes in FMEA as a result of internal and external complaints.

EXERCISES:

• Analyzing exemplary FMEA analyzes – “good” and “bad” patterns.
• Distinguishing between prevention and control – specific cases.
• Scoring the detection values ​​– classic and non-classical controls.
• Differentiation: defect-effect-cause.

CONTENTS:

• Risk analysis for selected processes/constructions.
• Assessment of archival analyzes.
• Improving the provisions in the field of control and prevention

EXERCISES:

• Creating a DFMEA / PFMEA analysis for selected processes – group  workshops.