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AS13004 - Failure Mode & Effects Analysis & Control Plans

Programme overview

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.

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 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 covers all of these standards and also addresses the risk-related requirements contained in the AS9100:2016 series of standards and is fully compliant with the FMEA & CP tools mandated in AS9145.

By the end of this 2-day practical 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 PFMEAs and Design DFMEAs - with special reference to the aerospace and defence sectors.

All participants attending the ‘public courses’ are requested to bring along an example of either a product ‘process layout diagram’ or a product design ‘P diagram’ for analysis

This course is classified as structured for continuing professional development (CPD) purposes by the CQI/IRCA.

Assessment of learning is achieved through structured exercises focused on an aerospace/defence Case Study. When run on site, actual FMEA exercises can replace the Case Study. The tutors provide feedback and advisement to ensure that risk-based thinking and associated best practices are fully understood in the context of the aerospace/defence industry.

The 2-day course is highly interactive and uses an Aerospace Case Study, quizzes and group exercises. The course timings are -

Day-1: 08:30 - 17:00

Day-2: 08:30 - 17:00

Programme details

The course is delivered over 2 consecutive days with continual assessment and feedback provided by the tutors.

Course topics include -

  • Understanding risk-based thinking and risk management
  • Systematising risk management
  • FMEA terminology explained
  • RPN (Risk Priority Number)
  • Sequence of the FMEA steps
  • Design FMEA – Example
  • Process FMEA – Example
  • Development of a Design FMEA
  • Development of a Process FMEA
  • Performing an FMEA
  • Identifying causes of failure
  • Developing effective actions
  • DFMEA & PFMEA linkages
  • Developing and documenting an FMEA procedure

Specific tools and methodologies required at various stages of the risk management is a process are included in the course -

  • FTA (Fault Tree Analysis)
  • Root cause diagnosis methodologies
  • “V” systems engineering model
  • Block (Boundary) Diagrams
  • FMEA Interface Matrix
  • P-Diagram (Parameter Diagram)
  • Process Flow Diagram
  • Alternatives to RPN prioritization (S-O-D and S-D prioritization tools)
  • DRBFM – Design Review Based on Failure Mode
  • DVP&R – Design Verification Plan and Report
  • Process Control Plan

Who should attend

Individuals needing to identify, manage and mitigate risks using best practice methodologies including FTA (Fault Tree Analysis), Design DFMEAs and Process PFMEAs plus a battery of related tools. The course covers all of the requirements mandated in AS13004 plus other standards/guidance documents relating to both DFMEAs and PFMEAs.

Having completed the course, individuals will be empowered to facilitate value-adding risk management projects that will form part of new product introduction (APQP & PPAP) standard AS9145. Apart from nominated ‘Team Leaders’ all persons needing to apply risk-based thinking and risk management will benefit from attending this course.

This is a TEC "Practitioner" course – consequently it incorporates "train-the-trainer".

Qualification

Students attending this course will receive a training certificate containing ASEQ and TEC logos.

Risk-based thinking is one of the three core concepts of the AS9100:2016 series of standards (and ISO 9001:2015). It is a structured approach to considering risk qualitatively and quantitatively when defining the rigour and degree of formality needed to plan and control the QMS (quality management system), as well as its component processes and activities - and, of course, the design and manufacture of products and manufacturing processes.

Organizations need to understand how they must apply risk-based thinking within their QMS, and in particular how it should be applied in respect of APQP (advanced product quality planning) and in all operations.Systematic risk management is becoming a basic expectation of the aerospace/defence ‘Primes’ and ‘Tier-1’ companies. Organizations offering risk management embedded in their QMS will have a distinct competitive advantage.

TEC's AESQ-approved 2-day course will quality and empower an organization’s cross-functional team members to undertake value-adding risk management projects that will form part of new product introduction (APQP & PPAP).

Competency will be demonstrated by the undertaking of either a design or process FMEA – using an organization’s own data

This course is classified as structured for continuing professional development (CPD) purposes by the CQI/IRCA. It contributes 16-hours to the required 45-hours of appropriate CPD for QMS Lead Auditors.

The individuals attending will learn how to use a set of powerful quality tools including the “V” systems engineering model, FTA (Fault Tree Analysis), DFMEAs, PFMEAs, DRBFM, DVP&R, Process Control Plans, and more.In addition they will be able to plan and manage risk management projects.

Resources

TEC Transnational Ltd are an Approved Training Partner to present CQI & IRCA certified courses (ATP Number: 01200706) Aerospace & Defence Risk Management & FMEA CPD Course Certificate (IRCA ref: C17843)

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