【英文課綱】10-new DFMEA Advanced Application Course Outline_En_Rev_20220728














































Training purpose:

1 According to the latest FMEA requirements issued by AIAG-VDA, combined
with rich practical application cases (production process actually in the
charge of trainees), explain the content, requirements, internal logic,
implementation steps and methods of FMEA.

2 It includes AIAG-VDA FMEA form, internal logic and filling
requirements, structure analysis, function analysis, correlation between
FMEA of different quality processes, previous failure mode investigation
and transfer and implementation of special characteristics in FMEA.

3 Teach how to use FMEA as a quality tool in the process of new product
process development; And the ideas, steps, skills, verification and
application methods of potential failure prevention in the aspects of
continuous improvement of key process engineering of existing products.

4 Master the strategies of enterprises to promote FMEA, share best
practices, learn how to apply FMEA for knowledge management, and form
enterprise technology precipitation and long-term technical
competitiveness.

Training characteristics

(1) Emphasis on practical application: it is promised to directly use the
part product / Process Engineering (the production process actually in the
charge of the trainees) for classroom FMEA practice and comment analysis,
which can ensure that the trainees have the practical ability to
independently write and develop their own high-quality FMEA after 2 days of
training.

(2) Advisory Teaching: it will be given by the consultant of the
international top R&D center who has rich experience in the practical
implementation and application of FMEA for vehicle and parts development,
and answer questions and doubts in an open manner, so as to know and say
everything about any relevant FMEA problems.

(3) Highly targeted: systematically analyze the key problems existing in
the implementation of FMEA, and put forward solutions and advice.

(4) The content is novel: explain the latest AIAG-VDA FMEA improvement
contents, such as SOD score, AP strategy and a variety of practical tools,
methods and tables, which greatly improve the practical application level
of engineers' FMEA.

(5) FMEA awareness and culture run through: share the consultant's long-
term best practice experience in implementing FMEA in the enterprise,
integrate failure prevention into the engineer's awareness and daily
habits, integrate it into the product development process, and rise to
enterprise behavior for comprehensive failure prevention and knowledge
management.



Implementation status of FMEA for failure prevention in Chinese Enterprises
″ Almost every quality consulting company will help customers with FMEA
(potential failure mode and impact analysis) training programs. However,
only a few cases have a happy ending. Even if the case is successfully
closed, after being trained, more than half of the enterprises found that
FMEA was like "chicken ribs" after doing it for a period of time!
″ Almost every automobile industry or company involved in the automobile
industry, whether vehicle manufacturers or parts suppliers, will require or
be required to do FMEA (potential failure mode and impact analysis).
However, few enterprises really benefit from it!
″ According to the statistics of the "comprehensive survey on the
application of quality tools", 89.4% of Chinese enterprises have not
achieved good results in promoting FMEA!
″ Therefore, so far, how to effectively prevent the failure of product
design and manufacturing rather than "fire fighting" afterwards is still
one of the most headache problems for enterprises.
In fact, there are two identification criteria for whether the enterprise
FMEA has been successfully imported:
λ Does FMEA help enterprises effectively prevent the failure of product
design and manufacturing- Failure prevention!
λ Does FMEA help enterprises carry out knowledge management to form
technology precipitation and long-term technical competitiveness- Knowledge
management!
To sum up, there are two root causes of PFMEA failure:
1、FMEA is not closely combined with the enterprise's product development
and manufacturing process, and the PFMEA that should have been prevented in
advance has become a "paper article" for post exercise.
Typical symptoms: system "idling", FMEA "idling", problem "lighting"
The annual review of the enterprise quality system has been carried out
every year. But the product quality problems of the enterprise still recur
and suffer. PFMEA has been done for 4 ~ 5 years, and hundreds of copies are
like waste paper. Failure prevention still depends on "natural brute force"
without rules and regulations.
2、Engineers do not really understand what PFMEA is and do not master the
method of developing high-quality FMEA.
Typical symptom: after FMEA is finished, the engineer doesn't want to see
it for the second time.
Because they did not understand the internal logical relationship of FMEA,
blindly copied the FMEA manual template form, lacked the ideas and methods
of PFMEA development, and simply relied on brainstorming to "crawl", the
failure mode, consequences and causes were confused. In addition, the risk
score was ambiguous. Such FMEA did not even want to see it for the second
time. How can they hope for failure prevention?
Our FMEA consultant is an experienced person in the implementation of
failure prevention FMEA in Chinese enterprises. We deeply understand and
understand the difficulties and expectations of Chinese enterprises in
implementing PFMEA. We refine and summarize the advanced application of
FMEA in manufacturing department for manufacturing process engineers based
on many years of experience in enterprise consulting services.
We adopt a highly interactive practical training method, and directly use
the parts products designed by the trainees themselves (the production
process actually in charge of the trainees) for classroom FMEA practice and
comment analysis, so as to ensure that the trainees have the practical
ability to independently write and develop their own high-quality FMEAs
through the training.
AIAG-VDA FMEA Main Update












































































Training Overview






























































AIAG-VDA FMEA Main Update






































































Training Schedule（2Days）
（Day1）
|Day |Topics |Details |Start|End |Dur |
| | | | | |ation |
| | |FMEA type and purpose, customer definition and| | | |
| | |application opportunity | | | |
| | |Introduction to DFMEA application |9:30 |10:3|1:00 |
| | | | |0 | |
| | |[why, under what circumstances, when, who and | | | |
| | |for whom DFMEA is done] | | | |
| | |Overall development steps of DFMEA | | | |
| | |DFMEA planning seven steps [how to integrate | | | |
| | |with product development process] | | | |
| |Coffee Break |10:30|10:4|0:15 |
| | | |5 | |
| |Design |Introduction to DFMEA practical function |10:45|12:0|1:15 |
| |FMEA 1st |template | |0 | |
| |Step: | | | | |
| |Planning &| | | | |
| |Preparatio| | | | |
| |n | | | | |
| | |[practice project initiation in combination | | | |
| | |with our own product DFMEA] | | | |
| | |Key points for filling in DFMEA header [FMEA | | | |
| | |date, key date, etc.] | | | |
| | |DFMEA team discussion method [DFMEA team | | | |
| | |formation] | | | |
| | |Previous failure mode investigation and | | | |
| | |prevention implementation in new project DFMEA| | | |
| |Lunch Break |12:00|13:0|1:00 |
| | | |0 | |
| |Design |→ Team exercises and comments (1): use the |13:00|14:3|1:30 |
| |FMEA 2nd |DFMEA function template issued to carry out | |0 | |
| |Step: |DFMEA exercises of real products / parts, | | | |
| |Structure |complete the analysis and development of DFMEA| | | |
| |Analysis |header, team and previous failure | | | |
| | |investigation stages | | | |
| | |Determination of DFMEA analysis scope - block | | | |
| | |diagram | | | |
| | |→ Team exercises and comments (2): continue | | | |
| | |the previous DFMEA exercises, complete the | | | |
| | |structural analysis diagram of DFMEA of real | | | |
| | |products / parts, and determine the analysis | | | |
| | |scope boundary of your own DFMEA | | | |
| |Coffee Break |14:30|14:4|0:15 |
| | | |5 | |
| |Design |Identification of customer functional |14:45|16:3|1:45 |
| |FMEA 3rd |requirements - interface function matrix / | |0 | |
| |Step: |p-diagram | | | |
| |Function | | | | |
| |Analysis | | | | |
| | |→ Team exercises and comments (3): continue | | | |
| | |the previous DFMEA exercises, complete the | | | |
| | |interface function matrix of the DFMEA of real| | | |
| | |products / parts, and automatically convert | | | |
| | |the items / functions in column 1 of the DFMEA| | | |
| | |table | | | |
| | |Supplier integration (DFMEA) | | | |
| | |All day summary and Q & A | | | |


|Day |Topics |Details |Start|End |Dur |
| | | | | |ation|
| | |DFMEA robust design correlation p-diagram | | | |
| | |(parameter diagram) | | | |
| | |Failure mode and consequence analysis | | | |
| | |skills | | | |
| | |Introduction to the difference between the | | | |
| | |new and old FMEA scoring criteria of | | | |
| | |severity s | | | |
| | |Transmission of classification, product |10:00|10:30|0:30 |
| | |special characteristics and previous | | | |
| | |effectiveness investigation | | | |
| |Coffee Break |10:30|10:45|0:15 |
| |Design |DFMEA failure cause / mechanism analysis |10:45|12:00|1:15 |
| |FMEA 5~6 |skills | | | |
| |Steps: | | | | |
| |Risk | | | | |
| |Analysis | | | | |
| |~ | | | | |
| |Optimizatio| | | | |
| |n | | | | |
| | |Logical relationship and confusion | | | |
| | |avoidance among failure mode consequence | | | |
| | |cause | | | |
| | |Frequency o introduction to differences | | | |
| | |between new and old FMEA scoring criteria | | | |
| | |Analysis skills of current design control | | | |
| | |measures | | | |
| | |Introduction to difference between new and | | | |
| | |old FMEA scoring criteria for detection D | | | |
| | |AP / RPN and the priority strategy of | | | |
| | |taking measures [emphasis in the new | | | |
| | |version] | | | |
| |Lunch Break |12:00|13:00|1:00 |
| |Design |→Team exercises and comments (4): continue |13:00|14:30|1:30 |
| |FMEA 7th |the previous DFMEA exercises and complete | | | |
| |Step: |the complete analysis of more than 2 | | | |
| |Results |failure modes in the DFMEA worksheet of | | | |
| |Documentati|real products / parts. | | | |
| |on | | | | |
| | |DFMEA quality assessment method | | | |
| | |DFMEA is associated with PFMEA | | | |
| | |DFMEA is associated with DVP & R (design | | | |
| | |verification plan report) | | | |
| |Coffee Break |14:30|14:45|0:15 |
| |-DRBFM |The new FMEA focuses on "change" failure |14:45|16:30|1:45 |
| | |prevention methods - DRBFM | | | |
| | |DRBFM application skills and examples | | | |
| | |→ Team exercises and comments (5): DRBFM | | | |
| | |based on the actual products of the | | | |
| | |enterprise | | | |
| |Q&A |Links between DFMEA and other quality tools| | | |
| | |[QFD, TRIZ, DOE, DFSS] | | | |
| | |Product life cycle quality tool strategy | | | |



Prerequisites
■ Basic process/ technical experience.
.

Course Methodology
? Breakout Exercises
– The exercies will be conducted during each training stage to
pratice FMEA, and also to evaluate the understanding of the
training courses.
– The purpose of breakout exercises is to develop skills of dfmea
Application by having individuals or teams working on practical
situations


? Evaluation of Individual Participation
– Attendees will be evaluated on class participation, which
encompasses the following aspects:
? Asking meaningful questions in class
? Sharing professional experiences
? Taking an active role in team exercises
– Effective class participation provides the attendee with
opportunities to demonstrate practical understanding of FMEA


? Certificate
– Certificate will be issued after satisfied participatings,
training performance evaluation.












The course has been trained for the following well-known enterprises and
has been highly recognized:













-----------------------
Base on AIAG-
VDA FMEA Edition版!


Advanced DFMEA Application for R&D
(AIAG-VDA New Edition DFMEA)
(2 Days Workshop )
2 Days Workshop


Your Trustable FMEA Professionals!

FMEA is only paper work?

“FMEA is just Paper Work, we can not see any use for quality improvement
except for showing auditors”
“We have more than hundreds of FMEA sheets, but same problems occur again
and again!”
“We have been trained numerous times for FMEA, but our engineers still
looks at FMEA as extra burden, what’s problem?”
“I’ve heard many top companies regard FMEA as top secret. But our FMEA is
cooked up by our engieers, we can not see why should it be secret? How to
manage and accumulate our knowledge with FMEA?”
“The field problems are most due to design reason. We are always fire
fighter, but fire comes out any time anywhere. If we can correct happened
problems, how could we prevent potential failures?”
“How to integrate FMEA with design process and kill the failure in the
early stage, and implement FMEA as tools intead of burdens.”
“Our engineers actually want to develop FMEA, but always alone without any
support. How to transfer FMEA job to Team Work?”
“How to build up the FMEA culture, and build FMEA methodology into the
working habit of each engineers?”
……

What are the benefits?

Emphasize practical application
Using customer on-site product for FMEA teaching, ensure every participant
fully understand how to develop high value-added FMEA
Rich experience of consultant
The professional consultant have rich FMEA experience in
vehicle/system/subsystem of GM, Samsung and Philips
Target at key issues
Using customer’s current FMEA files for problem analysis, and develop the
improvement planning combined with customer design process
Innovative Content
Most illustrative explanation from FMEA professionals, which are the key
writing committee of AIAG-VDA new FMEA manual
FMEA is process
Easy operational VBA-FMEA template for engineers application in their daily
work.

Who should attend?
Design Engineer,Procss Engineer, Industry Engineer,
QA/QC, SQE,Design Engineer
Process/ Design/Quality Strategy Management
Production/Design/Tech. Director or Manager
Product Manager, Project Manager

Tips
? Directly use Your Product to conduct FMEA practices in the workshop!
? This course target at FMEA impovement and application for engineers to
add value to FMEA process.
? Note: On-site training with FMEA project consulting！


If you are experiencing above pains, please contact us righ away！We will
help:
FMEA breakthrough solution！
FMEA dramatical Improvement！

DRBFM

DFMEA

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