AS13100 and RM13004: Design and Process Failure Mode and Effects Analysis and Control Plans 
I.D. # C1889 Duration 2 Days

In the Aerospace Industry there is a focus on Defect Prevention to ensure that quality goals are met. Failure Mode and Effects Analysis (PFMEA) and Control Plan activities are recognized as being one of the most effective, on the journey to Zero Defects.

This two-day course is designed to explain the core tools of Design Failure Mode and Effects Analysis (DFMEA), Process Flow Diagrams, Process Failure Mode and Effects Analysis (PFMEA) and Control Plans as described in AS13100 and RM13004. It will show the links to other quality tools such as Characteristics Matrix and Measurement Systems Analysis (MSA). The course will include hands on examples of FMEA deployment in a variety of typical manufacturing environments (including processing, machining and assembly) to illustrate how the technique is to be deployed. It will also describe the use of Reference Process FMEAs that can be used to minimize the duplication and reduce the time taken to produce an effective PFMEA whilst maintaining the required rigor.

Learning Objectives
By attending this seminar, you will be able to:
  • Explain the role of FMEA, PFDs, and Control Plans as part of a Defect Prevention System
  • Show the links to other Defect Prevention Tools such as APQP, Measurement Systems Analysis and PPAP
  • Evaluate and contribute to the Design FMEA activity
  • Complete a Process Flow Diagram (PFD) in line with AS13100 and RM13004 requirements
  • Lead the development of a Process FMEA on a manufacturing / assembly process
  • Assess Process Risks and prioritize actions
  • Identify appropriate risk mitigation improvement actions
  • Learn how to develop a Control Plan from the Process FMEA information
  • Create Reference Process FMEAs for future use in creating Part Specific PFMEAs
  • Provide the necessary skills and insight to effectively deploy RM13004 in any business

Who Should Attend

This course is designed for quality professionals in the aerospace engine manufacturing sector who seek compliance with AS13100 requirements in defect prevention specific to customer escapes. Both new and experienced quality practitioners should be trained in the PFMEA tools.

Participants should consider taking other courses in the SAE quality portfolio to support their competency with AS13100 tools. These courses include:
  • C2213 AS13100 Requirement for Advanced Product Quality Planning and Production Part Approval Process (coming soon)
  • C1878 AS13100 Measurement system Analysis (MSA) Requirements for Aerospace Engine Supplier Quality
  • C1862 AS13100 8D Problem Solving Requirements for Suppliers

Seminar Content
  • Achieving Zero Defects Using FMEA, PFDs, and Control Plans
    • Advanced Product Quality Planning System (APQP) and Production Part Approval Process (PPAP) Requirements
    • How the PFD, FMEA and Control Plan works within the APQP / PPAP System
  • Requirements Overview
    • AS13100 and RM13004 Background
    • The role of Cross Functional Team
    • Requirements of the Standard
    • Interpretations for Defect Prevention
  • Process Flow Diagrams
    • Types of Process Flow Diagrams
    • Case Study Exercise: Defining a Process Flow Diagram
  • Introduction to Failure Mode and Effects Analysis
    • Origins of FMEA
    • Product Liability and FMEA
    • The FMEA approach
    • Design FMEA Overview
  • Design Failure Mode and Effect Analysis
    • Evaluating a DFMEA
    • DFMEA Outputs for PFMEA
  • Process Failure Mode and Effects Analysis
    • Introduction to PFMEA
    • Walk through the PFMEA template

  • Process Failure Mode and Effects Analysis
    • Assessing the Risk Priority Number (RPN)
    • Prioritizing Improvement Actions
    • Keeping the PFMEA up to date
    • Case Study Exercise: Completing a PFMEA
    • Evaluating PFMEA examples
  • Control Plans
    • Walk through of the template
    • Using the Control Plan in Manufacturing and Assembly
    • Updating the Control Plan
    • Case Study: Creating a Control Plan from the PFMEA in the Case Study
  • Reference PFMEAs
    • What is a Reference PFMEA?
    • How to create a Reference PFMEA Library
    • Using Reference PFMEAs
    • Case Study: Creating a `Shell PFMEA¿ from Reference PFMEAs
  • Deploying AS13100 and RM13004
    • Establishing the current situation
    • Identifying the key components of a deployment plan
    • Evaluating progress
    • Resources
  • Course Assessment
    • Learning Assessment on all aspects of the syllabus, to confirm level of student Competence

Instructor(s): Suzanne Hill; Nicole Talbot

SuzzanelMrs. Suzanne Hill is the founding Director and Quality Executive of Assured Quality Improvements Limited (UK), a Quality and Business Improvement Management Consulting organization; facilitating Quality and Business Improvement, covering client manufacturing and logistics facilities, as well as Global Supply Chains. Suzanne is a Chartered Engineer (C.Eng IMechE) and Chartered Quality Professional (CQP CQI), with Business Management qualifications. She has worked within the global aerospace industry for over 25 years specializing in Gas Turbine Manufacturing Quality systems to EASA part21 subpart G regulations. In addition to strategy implementation, Suzanne¿s passion is manufacturing improvement; sizable aerospace work-places have gone from ¿chaos to order¿ in a matter of weeks under her facilitation. Suzanne is also globally recognized for her expertise in implementing robust problem resolution systems, inspector qualifications and training at all levels. She is a STEM ambassador and an assessor for the renowned IMechE Manufacturing Excellence awards in the UK.

NicoleMs.Talbot is an Industrial Engineer with a master¿s degree in engineering management from Université de Sherbrooke and a bachelor¿s degree in Industrial Engineering from Université du Québec à Trois Rivières, both in the province of Québec, Canada.¿ She is a certified CSSBB (Certified Six Sigma Black Belt) by the American Society for Quality, and has owned Services Techniques Nicole Talbot, Inc. for 13 years.¿Ms. Talbot has 30 years of experience in the automotive, aeronautics, food, wood and paper, energy, and services industries as a consultant, auditor, and instructor.¿Her expertise with leading manufacturers in aerospace has enabled her to evaluate, train, and improve the performance of quality systems across North America.

Fees: $1299 SAE Members: $1169


CEU 1.3