Training Agenda: FMEA (VDA) with Control Plan
Duration: 1 Day (8 Hours)
Audience: Engineers, Quality professionals, Project Managers, or anyone involved in risk management, product/process design, and quality control in automotive or manufacturing industries.
Registration & Welcome
- Attendees sign in.
- Introduction to the training objectives: Understanding FMEA and its integration with a Control Plan.
- Brief overview of the importance of FMEA and Control Plans in managing risks and ensuring process stability.
Introduction to FMEA (VDA) and Control Plan Concepts
- What is FMEA, and how is it used in risk management?
- Overview of the 7-step VDA FMEA methodology and its relevance.
- Introduction to the Control Plan: What it is, its purpose, and how it complements the FMEA.
- Importance of a structured approach to risk and control in the automotive industry.
Understanding the 7-Step VDA FMEA Process
- Planning and Preparation
- Defining the FMEA scope: DFMEA (Design) vs. PFMEA (Process).
- Forming a cross-functional team for a thorough analysis.
- Structure Analysis
- How to develop a structure tree to identify systems, subsystems, and components.
- Function Analysis
- Identifying functions and functional requirements for each system or component.
- Failure Analysis
- Identifying potential failure modes, causes, and effects.
- Activity: Participants identify failure modes for a sample product or process.
Morning Break
Risk Analysis and Optimization in VDA FMEA
- Risk Analysis
- How to rate Severity (S), Occurrence (O), and Detection (D) using VDA guidelines.
- Introduction to Action Priority (AP) as opposed to traditional Risk Priority Number (RPN).
- Optimization
- Strategies to reduce risks by addressing critical failure modes.
- Importance of identifying and documenting actions for risk reduction.
- Results Documentation
- Best practices for documenting FMEA findings and ensuring that FMEA remains a dynamic document.
- Activity: Participants complete a risk analysis and propose optimization actions for the identified failure modes.
Lunch Break
Introduction to Control Plans
- What is a Control Plan, and how does it integrate with FMEA?
- Structure of a Control Plan (Key components: Product/Process characteristics, control methods, reaction plans).
- Relationship between FMEA and Control Plans:
- How high-risk failure modes from FMEA are reflected in the Control Plan.
- Ensuring critical characteristics are controlled and monitored.
- Activity: Develop a basic Control Plan based on the FMEA completed earlier.
Linking FMEA and Control Plan in Practice
- How to ensure consistency between FMEA risk mitigation strategies and Control Plan actions.
- Assigning appropriate controls based on identified risks:
- Monitoring plans (e.g., Statistical Process Control, Inspection Frequency).
- Preventive actions for critical and high-priority risks.
- Activity: Participants refine their Control Plans by incorporating relevant risk mitigation actions from their FMEA.
Afternoon Break
Case Study – Integrating FMEA with Control Plan
- Group case study: Teams are provided with a real-world example to analyze.
- Each group performs an FMEA on a specific process/product, identifies risks, and develops a Control Plan that aligns with the FMEA.
- Presentations and discussions on group findings:
- How effectively the FMEA was integrated with the Control Plan.
- Lessons learned and practical applications in participants’ workplaces.
Wrap-Up & Q&A
- Recap of key learnings: Importance of the FMEA-Control Plan relationship for effective risk management.
- Open floor for questions, discussions, and feedback.
- Distribution of certificates