หลักสูตร Practical FMEA & Control Plan Workshop (AIAG & VDA Approach) หลักสูตร 2 วัน

In the automotive and manufacturing industries, organizations are increasingly required to manage product and process risks systematically in order to ensure product quality, safety, and customer satisfaction. Failure Mode and Effects Analysis (FMEA) has long been recognized as a critical risk prevention tool within the Advanced Product Quality Planning (APQP) framework. However, many organizations still encounter challenges when implementing FMEA effectively, such as treating it as a documentation exercise rather than a practical risk management tool, lacking clear linkage between Process Flow, FMEA, and Control Plan, or failing to translate risk analysis into actionable process controls.

To address these challenges, the Automotive Industry Action Group (AIAG) and the Verband der Automobilindustrie (VDA) jointly developed the AIAG–VDA FMEA Handbook, introducing a structured 7-Step Approach that enhances consistency, risk prioritization, and cross-functional collaboration. This updated methodology focuses on a systematic analysis of process structures, functions, failures, and risks, enabling organizations to identify potential issues early and implement effective preventive actions before they impact production or customers.

The Practical FMEA & Control Plan Workshop (AIAG & VDA Approach) is designed as an intensive hands-on training program that enables participants to understand and apply the AIAG–VDA FMEA methodology in real manufacturing scenarios. Through workshops, case studies, and group exercises, participants will learn how to conduct Process FMEA, evaluate risks using the Action Priority (AP) concept, and effectively translate FMEA results into a practical Control Plan. By the end of the program, participants will gain the capability to implement FMEA as a proactive risk management tool that strengthens process stability, improves product quality, and supports compliance with international automotive standards.

Training Objectives

   1.    To provide participants with a clear understanding of the AIAG–VDA FMEA methodology and its role within the APQP process.

   2.    To develop participants’ ability to systematically identify potential failure modes, causes, and effects within manufacturing processes.

   3.    To enable participants to evaluate process risks using Severity, Occurrence, Detection, and the Action Priority (AP) concept.

   4.    To strengthen participants’ capability to develop effective improvement actions that reduce process risks and enhance product quality.

   5.    To equip participants with practical skills to establish and link Control Plans based on FMEA results for effective process control and continuous improvement.

DAY 1 FMEA

Opening class to explanation the training purpose

   •   Pre-Test (ทดสอบก่อนอบรม)

FMEA Methodology

1.    Introduction to Risk Management in Automotive

   •    Role of FMEA in APQP

   •    Relationship between

      o    Process Flow

      o    FMEA

      o    Control Plan

   •    Common FMEA mistakes in industry

   •    Workshop - Identify process risks from a real production case

2.    Overview of AIAG & VDA FMEA

   •    Why FMEA changed from AIAG to AIAG-VDA

   •    Key differences from traditional FMEA

   •    Introduction to 7-Step Approach

3.    FMEA Step 1 – Planning & Preparation

   •    Define scope

   •    Build cross-functional team

   •    Define boundaries

   •    Workshop - Define FMEA scope from case study

4.    FMEA Step 2 – Structure Analysis

   •    Product / Process Structure

   •    Process Flow Diagram

   •    Process breakdown

   •    Workshop - Create structure tree

5.    FMEA Step 3 – Function Analysis

   •    Function of process

   •    Requirements

   •    Failure logic

   •    Workshop - Identify process function

6.    FMEA Step 4 – Failure Analysis

   •    Failure Mode

   •    Failure Effect

   •    Failure Cause

   •    Workshop - Identify failure modes from process

7.    FMEA Step 5 – Risk Analysis

   •    Severity

   •    Occurrence

   •    Detection

   •    Explain Action Priority (AP) concept

   •    Exercise - Evaluate risk

ทบทวนและสรุปก่อนจบหลักสูตร Review overall training in Day one.

   •    Key Takeaways & Key Clauses

   •    Q&A

DAY 2 FMEA and link to control plan

Review day 1

8.    FMEA Step 6 – Optimization

   •    Define improvement actions

   •    Risk reduction strategies

   •    Workshop - Develop corrective actions

9.    FMEA Step 7 – Documentation

   •    FMEA report

   •    Update and maintenance

   •    Link to lessons learned

Control Plan

1.    Control Plan Concept

   •    Purpose of Control Plan & Relationship

   •    Types of Control Plan

      o    Prototype

      o    Pre-launch

      o    Safe launch

      o    Production

2.    Control Plan Element

   •    Process Step

   •    Product Characteristices

   •    Process characteristics

   •    Control method and frequency

   •    Reaction Plan and Responsible

   •    Workshop - Build control plan from FMEA

3.    Linkage Between FMEA & Control Plan

   •    How high-risk items in FMEA become controls in Control Plan

   •    High severity → special characteristic

   •    Detection method → inspection

   •    Workshop - Create structure tree

4.    Practical Case Study (Workshop) - Participants work in groups, activity

   •    Create Process Flow

   •    Build Process FMEA

   •    Evaluate Risk

   •    Develop Control Plan

Final Session

Common Problems in FMEA & Control Plan

   •    FMEA done only for documents

   •    Control Plan not linked with real process

   •    Reaction plan not defined

   •    Verify effectiveness of control plan

ทบทวนและสรุปก่อนจบหลักสูตร Review overall training in Day one.

   •    Key Takeaways & Key Clauses

   •    Q&A

   •    Post Test

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