VDA FFA training builds the competence needed to analyse parts returned from the field in a structured way and to feed the results back into the product and the process.
Field Failure Analysis (FFA) is the approach published by the VDA that establishes a common analysis language between the vehicle manufacturer and the supplier in the automotive supply chain.
Why is a common method needed?
A part returned from the field is the topic that generates the most disputes between the supplier and the OEM.
The supplier tests the part and finds no problem; the OEM knows there is a real complaint in the field. When the two sides work with different methods, different test conditions and different criteria, the result turns into an argument and nobody learns.
VDA FFA aims to solve this problem with a common process, common terminology and common evaluation criteria.
No-trouble-found cases
This is the most critical topic of the analysis. What happens when testing of the part returned from the field cannot identify any problem?
These cases both generate cost and produce no learning. Moreover, as vehicle architecture grows more complex and electronic and software content increases, their share rises.
VDA FFA prescribes that instead of arbitrarily closing these cases as “no problem”, they are handled systematically, the test conditions are compared with the real usage conditions, and the case is evaluated together with the OEM.
Who should attend?
- Field quality and warranty officers
- Quality managers and quality engineers
- Test and laboratory officers
- Product development and design engineers
- Teams running customer complaint processes
- After-sales and technical support teams
There are no prerequisites.
Training Content
Fundamentals
- The scope and purpose of field failure analysis
- The sharing of roles between the OEM and the supplier
- Common terminology and evaluation criteria
- Its relationship with warranty processes
The analysis process
- The part return flow and delivery conditions
- Pre-examination and classification
- Preparing the test plan
- Simulating the real usage conditions
- Evaluating and reporting the results
No-trouble-found cases
- Defining the case correctly
- Questioning the test conditions
- Joint evaluation with the OEM
- Analysing recurring cases
Feedback
- Conducting the root cause analysis
- Reflecting the findings in the FMEA and the control plan
- Corrective action and effectiveness verification
- Transferring lessons learned to new projects
Practical exercises
Participants set up an analysis plan and carry out evaluations using sample cases.
Learning Outcomes
- Analysing field returns in a structured way
- Managing no-trouble-found cases
- Setting up the test and examination process
- Conducting joint evaluations with the OEM
- Feeding the findings back into design and process
Duration and Participation Options
Duration: 2 days in open-enrolment programmes. In in-house programmes, planned as 1–3 days depending on the scope and participant profile.
Participation type: Open enrolment or in-house.
Training method: In person (at your organization or in our training room), live online, on-demand recording.
Dates: Set according to demand.
Certificate of Attendance
Participants who complete the training receive a certificate of attendance. The certificate includes the participant’s name, training scope, date and duration. It can be used as evidence of competence in your competence records and in audits.
- CQI-14 Training — automotive warranty management
- CQI-20 Training — effective problem solving
- AIAG-VDA FMEA Training
- PSCR Training — product safety and conformity
Beyond Training: Implementation Support
- Setting up the field failure analysis process
- Preparing the test and examination protocols
- Work aimed at reducing no-trouble-found cases
- Support for joint evaluation processes with the OEM
You can make use of our consulting services in every area where support is needed.
Frequently Asked Questions About VDA FFA Training
What is VDA FFA?
Field Failure Analysis is the approach published by the VDA for analysing parts returned from the field in a structured way. It establishes a common analysis language between the OEM and the supplier.
What does a no-trouble-found case mean?
It is the situation where testing of a part returned from the field cannot identify any problem. It generates cost but produces no learning; its share rises as vehicle architecture grows more complex.
Why is a common method needed?
When the supplier and the OEM work with different methods, different test conditions and different criteria, the result turns into an argument and nobody learns. A common process and terminology aim to solve this problem.
What is the difference between VDA FFA and CQI-14?
CQI-14 is the AIAG guideline addressing warranty management as a whole. VDA FFA is the VDA approach focusing on the technical analysis of the part returned from the field. The two complement each other.
What should we do if the test finds no problem?
Instead of closing the case as ‘no problem’, you need to question whether the test conditions match the real usage conditions and evaluate the case together with the OEM.
How long does VDA FFA training take?
Open-enrolment programmes take 1-2 days. In in-house programmes the work is done on your own field cases.