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e-Learning: AS13004 – Process Failure Mode and Effects Analysis (PFMEA) and Control Plans

Programme overview

AS13004 was created by the Aerospace Engine Supplier Quality (AESQ) Committee to establish a common practice for effective process risk identification, assessment, mitigation, and prevention.

AS13004 defines a methodology to mitigate risk using Process Flow Diagrams (PFDs), Process Failure Mode and Effects Analysis (PFMEA), and Control Plans (CPs). It is to be used by organizations throughout the life cycle of a product. FMEA (Failure Mode and Effects Analysis) is a methodology for identifying, assessing, and prioritizing risks of different kinds. Once the risks have been identified, the organization will manage a plan to minimize or eliminate the impact of negative events on the manufacturing process.

This course meets in full the requirements of AS13004 - Process Failure Mode and Effects Analysis (PFMEA) and Control Plans published by the AESQ (Aerospace Engine Supplier Quality) Strategy Group. TEC are an approved AESQ Training Provider, and the face-to-face version of this course has been formally approved by PROBITAS Authentication on behalf of the AESQ.

There are a number of risk management standards, including AS13004, ISO 31000, ISO 17666, ARP5580 and J1739. The course focuses on AS13004 and also addresses the risk-related requirements contained in the AS9100 series of standards and is fully compliant with the PFC, FMEA & CP tools mandated in AS9145.

After completing this e-Learning course, participants will have learned from scratch how to understand and apply risk-based thinking and risk management and be able to undertake value-adding Process Flow Diagrams (PFD), Process Failure Modes and Effects Analysis (PFMEA) and Control Plans (CPs) – with special reference to the aerospace and defence sectors.

A combination of quizzes, tests and personal assignments are used to ensure understanding of the principles and practices involved.

The objective is to qualify practitioners who will be ‘subject experts’ able to lead cross-function teams to undertake all of the activities included in the AS13004 standard. All learners are requested to have a copy of the latest revision of AS13004 – Process Failure Mode and Effects Analysis (PFMEA) and Control Plans during the e-Learning course.

Programme details

Introduction to risk management and AS13004

  • Introduction
  • Understanding risk-based thinking
  • Reasons for risk management and mitigation
  • The AS13004 standard
  • Test: AS13004 creation and focus

Risk-related terms & acronyms and their definitions

  • ISO 9000 terminology
  • Personal assignment: review of AS13004 terms and definitions
  • Test: locating/understanding AS13004 terms and definitions
  • Test: review of AS13004 acronyms
  • IAQG listing of aerospace/defence terminology

Prerequisites of AS13004

  • Essential AS13004 inputs
  • Design for Manufacturing and Assembly (DFMA)
  • Test: DFA, DFM and DFMA features and differences
  • Design Failure Mode and Effects Analysis (DFMEA)
  • Test: DFA, DFM, DFMA & DFMEA activities
  • Design of the manufacturing process -Test: steps in the design of the manufacturing process

Purpose, applicability and scope of AS13004

  • Purpose of AS13004
  • Applicability of AS13004
  • Test: AS13004 purpose and applicability
  • Scope of AS13004
  • Cross-functional Teams
  • Test: AS13004 scope and activities

Process Flow Diagrams (PFDs)

  • PFD inputs
  • Quiz: Product design information
  • High-Level Process Map
  • Mapping the operations
  • Defining the operation deliverables/outputs
  • Identifying ‘Special Requirements’
  • Identifying Sources of Variation
  • Characteristic Matrix
  • Summary of PFD activities
  • Test: understanding Process Flow Diagrams (PFDs)
  • PFD alternative formats
  • Customer preferences for PFD formats
  • Personal assignment: customer-specific PFD requirements
  • Outputs of the PFD
  • Quiz: PFD outputs
  • Revision control of PFD

Process Failure Mode and Effects Analysis (PFMEA)

  • Overview of a PFMEA
  • PFMEA guiding principles
  • PFMEA-related terms and their definitions
  • Test: PFMEA-related terms and their definitions
  • Prerequisites for a PFMEA
  • AS13004 PFMEA input requirements
  • Quiz: PFMEA inputs and prerequisites
  • Recording the PFMEA steps
  • Personal assignment: customizing a PFMEA spreadsheet
  • Sequence of the PFMEA steps
  • Explanation of the PFMEA steps
  • Test: identifying the sequence of the PFMEA steps

Elements of the PFMEA form

  • Item
  • Process Function
  • Failure Mode
  • Effect
  • Cause
  • Controls
  • Test: matching information to PFMEA form elements

Quantifying severity, occurrence and detection

  • Ranking criteria
  • Severity
  • Occurrence
  • Detection
  • Quiz: severity, occurrence and detection
  • Assigning ‘rankings’ to S, O and D
  • Test: Quantifying S, O & D using the AS13004 ranking criteria
  • Risk Priority Number
  • Test: calculating RPNs
  • Understanding RPN ‘thresholds’
  • Test: identifying the need for recommended action
  • Alternative to basic RPN prioritization
  • Personal assignment: customizing a revised PFMEA spreadsheet
  • Using the S-O-D prioritization tool
  • Test: using the S-O-D prioritization tool

Actions to mitigate risk and reduce RPN

  • Prioritizing action plans
  • Systematizing action plans
  • Reducing severity
  • Reducing occurrence
  • Reducing detection
  • Rescoring the S, O, D – and the ‘new’ RPN
  • Quiz: mitigating risk and reducing RPN
  • Outputs of the PFMEA
  • Quiz: mandatory outputs of the PFMEA
  • Revision control of PFMEA

Control Plan

  • Overview of the control plan
  • Control plan prerequisites
  • Quiz: CP prerequisites
  • Control plan – key elements
  • Personal assignment: creating your organization’s CP
  • Control methods
  • Quiz: typical control methods
  • Reaction plan
  • Quiz: Reaction plan
  • Revision control of CP

Training, Competency and the QMS

  • AS13004 training requirements
  • Quality Management System requirements

Programme benefits

The objective is to qualify practitioners who will be ‘subject experts’ able to create Process Flow Diagrams (PFDs), undertake effective Process Failure Mode and Effects Analysis (PFMEA) and develop Control Plans (CPs).

Having completed this e-Learning course, individuals will be empowered to facilitate value-adding PFMEA projects that will form part of new product introduction (APQP & PPAP) standard AS9145.

This e-Learning course is identical to TEC’s face-to-face course which has been formally approved by PROBITAS Authentication on behalf of the AESQ.

Buy now

Buy e-Learning: AS13004 – Process Failure Mode and Effects Analysis (PFMEA) and Control Plans

The course is delivered as an online e-Learning module via the TEC Transnational Ltd learning platform. Set quantity and provide email addresses for learners at checkout.

e-Learning: AS13004 – Process Failure Mode and Effects Analysis (PFMEA) and Control Plans

£295

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