AS13004 - Failure Mode & Effects Analysis & Control Plans

Risk-based thinking (and management) is a process 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.

A variety of strategies are available, depending on the type of risk and the type of business. There are a number of risk management standards, including AS13004, ISO 31000, ISO 17666, ARP5580 and J1739. FMEA scoring criteria from all of these sources are included.

This course meets in full the requirements of AS13004 - Process Failure Mode and Effects Analysis (PFMEA) and Control Plans

This course addresses all of the risk-related requirements contained in the AS9100:2016 series of standards and is fully compliant with the above standards and the APQP & PPAP 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

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
Public course

Our public courses are run at the Woodland Grange Conference Centre in Warwickshire

The course fee includes a 3-course lunch and refreshments on each training day

Course dates
On-site course

In-company courses may be organised at any time and are extremely cost-effective on a ‘cost-per-student’ basis. The host company is responsible for the venue costs.

We can accommodate up to 10 (maximum) delegates per session.


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".

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 2-day course will 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.

Larger teams might benefit from our in-house courses. Fill out the form below and we will contact you with further details.

We will only ever user your information to process your enquiry in accordance with our privacy policy. If you join our mailing list your name email will processed by Mailchimp.