FMEA training is designed for teams who want to identify potential failures in products and processes before they occur and take preventive action.
FMEA (Failure Mode and Effects Analysis) is a risk method that systematically analyses potential failure modes, their effects and their causes. In automotive, its application is expected under
IATF 16949.
The FMEA handbook jointly published by
AIAG and
VDA was the first Core Tool to merge two separate traditions into a single framework. AIAG’s 4th edition, however, can still appear as a reference in some customer requirements; you need to confirm which approach is expected of you from your
customer-specific requirements.
What the joint handbook brings
The seven-step approach. The analysis is no longer a form-filling exercise but a process with defined steps: planning and preparation, structure analysis, function analysis, failure analysis, risk analysis, optimization, results documentation.
Action Priority instead of RPN. In place of the risk priority number based on multiplying severity, occurrence and detection, a logic was introduced that assigns high, medium or low priority according to the combination of the three values.
The reason for this change was practical: the multiplication method allowed different combinations to produce the same number and high-severity failures to slip through with a low score. The new approach puts severity first.
Structure and function analysis. The analysis no longer starts directly from failure modes; the structure and functions of the system are mapped first. In practice this is the step that meets the most resistance but raises analysis quality the most.
FMEA for monitoring and system response. For systems containing electronics and software, an additional analysis type was defined covering failure detection and response mechanisms under field conditions.
The most common mistake
Preparing the FMEA once and archiving it. Yet it is expected to be a living document: it should be updated when the process changes, when a customer complaint arrives, when a field incident occurs, when a similar product is launched.
A finding frequently seen in audits: a failure occurred in the field, a
corrective action was opened, but the PFMEA was never touched.
Who should attend?
- Product and process development engineers
- Quality engineers and quality managers
- Production and industrial engineers
- Project and launch officers
- Maintenance and equipment officers
- IATF 16949 internal auditors
- Supplier quality development teams
FMEA is teamwork; participation from different functions increases the impact of the training.
Training Content
Fundamentals
- The purpose of FMEA and its place in risk management
- DFMEA, PFMEA and the complementary analysis types
- Team set-up, defining the scope and preparation
- The place of FMEA within the APQP phases
The seven steps
- Planning and preparation
- Structure analysis
- Function analysis
- Failure analysis
- Risk analysis
- Optimization
- Results documentation
Evaluation and prioritization
Determining the severity, occurrence and detection values, the Action Priority logic, action planning and re-evaluating effectiveness are addressed.
The link with the other tools
Transferring FMEA outputs to the
Control Plan, the relationship with
SPC sampling frequency and its place in the
PPAP file are shown.
Sustaining the FMEA
Update triggers, transferring lessons learned, the foundation FMEA approach and document management are covered.
Practical exercises
Participants prepare an FMEA by applying the seven steps to a product or process. In in-house programmes the work is done on your own products and produces directly usable output.
Learning Outcomes
- Applying the seven-step approach
- Preparing a DFMEA and a PFMEA
- Using the Action Priority logic correctly
- Transferring FMEA outputs to the control plan
- Sustaining the FMEA as a living document
- Defending the FMEA in customer audits
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 depth of the practical work.
Participation type: Open enrolment or in-house.
Training method: In person (at your organization or in our training room), live online, on-demand recording.
Obtaining the manuals: AIAG and VDA publications are copyright-protected and are not provided as part of the training. Participants need access to the current edition.
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 customer audits.
Related Trainings
Beyond Training: Implementation Support
- Moderation of FMEA workshops
- Review of your existing FMEAs
- Establishing the FMEA–Control Plan link
- Building the foundation FMEA structure
- Preparation before the customer audit
You can make use of our
consulting services in every area where support is needed.
Frequently Asked Questions About FMEA Training
What is the difference between the AIAG & VDA FMEA handbook and AIAG’s 4th edition?
The joint handbook merges the AIAG and VDA approaches into a single framework; it introduces the seven-step structure and the Action Priority logic. AIAG’s 4th edition can still be a reference in some customer requirements; confirm which one is expected from your customer-specific requirements.
Why was the RPN removed?
The multiplication-based risk priority number allowed different combinations to produce the same number and high-severity failures to slip through with a low score. The Action Priority approach looks at the combination of the three values and puts severity first.
Why are the seven steps important?
Doing the structure and function analysis first, instead of starting the analysis directly from failure modes, allows the failure modes to emerge systematically. In practice these are the steps that meet the most resistance but raise analysis quality the most.
When must the FMEA be updated?
When the process or design changes, when a customer complaint arrives, when a field incident occurs, when a new failure mode is identified and when a similar product is launched.
What is the difference between DFMEA and PFMEA?
DFMEA analyses failure modes originating from the design, PFMEA those originating from the production process. The two feed each other but one does not replace the other.
Can one person prepare the FMEA?
The method requires teamwork. Participation of design, production, quality, maintenance and, when necessary, supplier representatives is expected. FMEAs prepared by a single person are frequently found inadequate in audits.
Can we work on our own product in FMEA training?
Yes. In in-house programmes all practical exercises are run on your own products and processes; this format produces directly usable output.
How long does FMEA training take?
Open-enrolment programmes take 2 days. In-house programmes are planned as 1-3 days depending on content density.