AS13004: Process Failure Mode and Effects Analysis (PFMEA) and Control Plans C1889

Topics: Quality, Safety & Maintenance

In the Aerospace Industry there is a growing focus on Defect Prevention to ensure that quality goals are met. Process Failure Mode & Effects Analysis (PFMEA) and Control Plan activities described in AS13004 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 Process Flow Diagrams, Process Failure Mode & Effects Analysis (PFMEA) and Control Plans as described in AS13004. It will show the links to other quality tools such as Design FMEA, Characteristics Matrix and Measurement Systems Analysis (MSA). The course will include hands on examples of PFMEA 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:

  • Evaluate and contribute to the Design FMEA activity
  • Complete a Process Flow Diagram (PFD) in line with AS13004 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
  • Set out a deployment strategy for your business for AS13004

Who Should Attend

This course is intended for personnel developing, qualifying and implementing the essential requirements to establish an acceptable PFMEA program for use on aero engine parts and assemblies.



You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

  • Defect Prevention System Overview
    • Advanced Product Quality Planning System (APQP) & Production Part Approval Process (PPAP) Requirements
    • How the PFD, FMEA and Control Plan works within the APQP / PPAP System
  • AS13004 Standard Overview
    • Structure of the Standard
    • 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 & Effects Analysis
    • Origins of FMEA
    • Product Liability & FMEA
    • The FMEA approach
    • Design FMEA Overview
    • Overview of the DFMEA process
    • Evaluating a DFMEA
    • DFMEA Outputs for PFMEA
  • Process Failure Mode & Effects Analysis
    • Introduction to PFMEA
    • Walk through the PFMEA template
  • Process Failure Mode & 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 & 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 AS13004
    • 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
Suzanne Hill

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.

Duration: 2 Days
CEUs: 1.3

Format: Virtual

Event ID: LM117

Location: Live Online

Session Info:

  • Session 1 - March 16 (7:00 a.m. - 3:00 p.m. ET)
  • Session 2 - March 17 (7:00 a.m. - 3:00 p.m. ET)
    2 Sessions

  • Fees: $1,299.00

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