Course Overview

This course covers PFMEA and Control Plan requirements for AS13004 – Process Failure Modes and Effects Analysis and Control Plan (including an overview of DFMEA). This course outlines the competitive advantages of an effective FMEA process along with the benefits of value added controls with the control plan.
FMEA is an analytical method to ensure potential problems have been considered, assessed for risk and actioned as part of product and process design. It provides a record of an organisations collective knowledge about its products and processes. The intent of the control plan is to document and provide value added controls in support of the PFMEA process. Implementation of an effective PFMEA and control plan process form key foundation activities in support of the zero defect goal.

This course has been endorsed by Rolls-Royce civil aerospace and the AESQ as meeting the requirements for supplier training to the AS13004 standard.

Who should attend?

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.

Benefits and Learning Objectives

FMEA is used to support the introduction of new products and processes as well as supporting changes to existing products and processes. It supports the goal of zero defects, defect prevention and the reduction of variation and waste. Companies that apply PFMEA and Control Plans well 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 Effects Analysis and Control Plans within their organisation.

Topics covered

FMEA General

  • System of defect prevention tools
  • Purpose and history of FMEA
  • Introduction to, scope of AS13004
  • Risk and types of risk management
  • FMEA considerations and application
  • Cross functional teams
  • Define the customer
  • FMEA steps and recommended actions
  • FMEA pitfalls
  • FMEA types

 

 

 

Design 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
  • Recommended actions and review

 

Process FMEA

  • AS13004 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, AS13004 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

Why choose Industry Forum

Industry Forum helps major global manufacturers understand, optimise and improve both manufacturing capability and business performance.

An integrated team of consultants and practitioners – all seasoned expert engineers with multi-sector manufacturing experience – Industry Forum brings together a world-class combination of improvement competency, insight, process and best practice.

Spanning automotive, aerospace, consumer appliance, electronics and food sectors, for over 20 years Industry Forum has planned and delivered some of the world’s most consistent and successful transformations for business-critical manufacturing operations.

Our trainers are expert practitioners in Aerospace Management Systems with hands-on industrial experience and highly developed communication skills. They have a wealth of technical expertise and often provide on-site advice and coaching. During every course we will encourage collaboration and sharing of practical experiences, ensuring learning can be put into context and empowering delegates to apply their new skills successfully in their workplace as well as making sustainable improvements

Downloads

Certification

Upon completion of the course you will receive an Industry Forum AS13004 PFMEA and Control Plan Practitioner Certificate.

Course booking details

DatesVenueCostAvailabilityTake Action
08/07/2019 - 09/07/2019Birmingham (UK)£475 (ex. VAT)Spaces AvailableBook Now
14/10/2019 - 15/10/2019Birmingham (UK)£475 (ex. VAT)Spaces AvailableBook Now