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FMEA in Practice DFMEA, PFMEA & the 7-Step Method
Published 9/2026
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Language: English | Duration: 1h 27m | Size: 1.31 GB
Master DFMEA and PFMEA using both the traditional and AIAG VDA 7-step approach - Live Practical Automotive Case Study
What you'll learn
Apply the AIAG-VDA 7-step FMEA approach to practical product and manufacturing risks.
Build DFMEAs and PFMEAs using a structured engineering methodology.
Apply the traditional approach of risk priority number RPN for developing FMEA/DFMEA
Perform Structure and Function Analysis before identifying potential failures
Correctly distinguish Failure Effects, Failure Modes and Failure Causes
Evaluate risk using Severity, Occurrence and Detection and understand the limitations of traditional RPN
Understand how PFMEA information feeds the Control Plan
Understand Action Priority and use FMEA optimisation to drive meaningful risk reduction
Develop and track recommended actions, responsibilities, completion evidence and residual risk
Connect DFMEA → Process Flow → PFMEA → Control Plan → MSA → SPC → PPAP using a worked automotive case study
Requirements
No previous PPAP experience is required
Basic knowledge of manufacturing or quality is helpful but not essential
Microsoft Excel or compatible spreadsheet software is recommended for working through the supplied PPAP template
An interest in general quality, supplier quality, manufacturing engineering or quality management
Description
Learn FMEA by analysing a real product and manufacturing process - not by memorising risk tables.
Failure Mode and Effects Analysis is one of the most important preventive quality tools used in automotive and manufacturing environments. But effective FMEA is about much more than assigning Severity, Occurrence and Detection numbers.
A strong FMEA requires you to understand what the product or process must do, how that function could fail, what would happen if it failed, what could cause the failure, what controls already prevent or detect it, and what should be done to reduce the risk.
This course teaches you how to answer those questions systematically using an ADC12 aluminium automotive water pump housing through both Design FMEA (DFMEA) and Process FMEA (PFMEA).
THE 7-STEP FMEA APPROACH
Step 1 - Planning & Preparation
Define scope, boundaries, assumptions, team, timing and relevant lessons learned.
Step 2 - Structure Analysis
Break the product or manufacturing process into logical elements.
Step 3 - Function Analysis
Identify what each product element or process step is required to do and its associated requirements.
Step 4 - Failure Analysis
Build the relationship: Failure Effect → Failure Mode → Failure Cause.
Step 5 - Risk Analysis
Evaluate Severity, Occurrence, Detection, prevention controls, detection controls and Action Priority.
Step 6 - Optimisation
Develop meaningful risk-reduction actions, owners, target dates and closure evidence, then reassess residual risk after implementation.
Step 7 - Results Documentation
Summarise important risks, actions, residual risk and downstream impact.
BUILD A PRACTICAL DFMEA
Using the ADC12 water pump housing, analyse product functions and potential design failures involving the main bore, sealing interfaces, housing pressure boundary, mounting interfaces, dimensional requirements, leakage and product performance.
BUILD A PRACTICAL PFMEA
Analyse manufacturing operations including casting, machining, deburring, cleaning, dimensional inspection, leak testing and final verification. Follow risks such as main-bore machining variation and translate credible causes into prevention and detection controls.
UNDERSTAND ACTION PRIORITY - NOT JUST RPN
The course explains traditional RPN so students can understand existing and legacy FMEAs, while also teaching why risk decisions should not rely only on an arbitrary numerical threshold. Students learn the Action Priority approach and the principle that ratings should not be manipulated simply to make risk appear acceptable.
LEARN THE GOLDEN THREAD
Product Function → DFMEA Risk → Design Requirement / Special Characteristic → Manufacturing Process → PFMEA Risk → Control Plan → MSA → SPC & Process Capability → PPAP.
PRACTICAL DOWNLOADABLE FMEA EXCEL WORKBOOK
The workbook includes
• FMEA 7-Step Roadmap
• DFMEA Structure Analysis
• Function Analysis
• Worked DFMEA
• PFMEA training view
• Worked PFMEA
• Action Priority training structure
• FMEA Optimisation & Action Tracker
• Residual Risk Review
• FMEA Summary
• Core Tools Golden Thread
• Worked ADC12 automotive case study
BY THE END OF THIS COURSE
Students should be able to approach an unfamiliar product or manufacturing process and systematically determine its functions, potential failures, effects, causes, existing controls, risk, appropriate actions and downstream manufacturing controls. The objective is not simply to complete an FMEA spreadsheet, but to think like an effective FMEA team member.
What Students Will Learn
• Apply the AIAG-VDA 7-step FMEA approach to practical product and manufacturing risks.
• Build DFMEAs and PFMEAs using a structured engineering methodology.
• Perform Structure and Function Analysis before identifying potential failures.
• Correctly distinguish Failure Effects, Failure Modes and Failure Causes.
• Evaluate risk using Severity, Occurrence and Detection and understand the limitations of traditional RPN.
• Understand Action Priority and use FMEA optimisation to drive meaningful risk reduction.
• Develop and track recommended actions, responsibilities, completion evidence and residual risk.
• Connect DFMEA → Process Flow → PFMEA → Control Plan → MSA → SPC → PPAP using a worked automotive case study.
Course Requirements
No previous FMEA experience is required. Basic knowledge of manufacturing, engineering or quality is helpful but not essential. Students should have Microsoft Excel or compatible spreadsheet software if they wish to follow and reuse the downloadable FMEA workbook. Students working in automotive quality will benefit from access to the applicable official FMEA manuals and their organisation's/customer's rating criteria for live applications.
Who this course is for
• Quality Engineers who create, review or audit FMEAs.
• Supplier Quality Engineers responsible for supplier DFMEA/PFMEA review and development.
• Design Engineers involved in product-risk analysis and DFMEA.
• Manufacturing and Process Engineers responsible for PFMEA and process-risk reduction.
• APQP and NPI Engineers responsible for product and process launch.
• Quality Managers responsible for Core Tools implementation.
• Engineers moving into automotive or IATF 16949 manufacturing environments.
• Engineering and quality students who want practical FMEA experience rather than theory alone.
• Professionals who currently use traditional RPN-based FMEA and want to understand the 7-step and Action Priority approach.
Who this course is for
Supplier Quality Engineers and Supplier Quality Managers
Quality Engineers and Quality Managers
Manufacturing and Process Engineers
APQP and PPAP Engineers
New Product Introduction (NPI) Engineers
Supplier Development Engineers
Automotive and manufacturing professionals
Quality inspectors and metrology professionals moving into quality engineering
Engineering graduates seeking practical PPAP knowledge
Suppliers preparing PPAP submissions for customers
Professionals preparing for interviews or roles involving PPAP, APQP and supplier quality
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