PFMEA Capability Building & Implementation
Build hands-on capability to identify, prioritise, and mitigate manufacturing process risks using the AIAG-VDA PFMEA methodology, with practical application to real manufacturing challenges.
This programme is designed to build practical PFMEA capability within manufacturing teams using the AIAG-VDA 7-Step PFMEA methodology. The training combines PFMEA fundamentals with hands-on application across process mapping, function and failure analysis, risk prioritisation, preventive and detective controls, optimization, and PFMEA–Control Plan linkage. Participants work on real manufacturing processes to identify potential failure modes, assess risks, develop improvement actions, and strengthen a proactive approach to defect prevention and operational excellence.
Course curriculum
Foundation
Day 1 – PFMEA Fundamentals & Manufacturing Risk Assessment
Module 1
Manufacturing Risk Assessment
Proactive risk identification, defect prevention, operational excellence and integration of PFMEA with Process Flow, Control Plans, APQP and continuous improvement.
Module 2
PFMEA Concepts & AIAG-VDA Framework
PFMEA fundamentals, evolution of FMEA, AIAG-VDA 7-step approach and prevention-based versus detection-based controls.
Module 3
Manufacturing Case Studies
Real-world examples of failure prevention, quality improvement and lessons from automotive and industrial manufacturing.
Module 4
Process Understanding & Risk Identification
Mapping risks across processing, welding, glazing, packaging and profile cutting, with cross-functional failure mode identification.
Practical activity: Team-based process risk identification and presentations.
Application
Day 2 – AIAG-VDA 7-Step PFMEA Application
Module 5
PFMEA Team Formation
Cross-functional team responsibilities, project selection and PFMEA scope definition.
Module 6
Planning & Structure Analysis
Steps 1–2: Process boundaries, project planning, process hierarchy, work elements and process flow mapping.
Module 7
Function & Failure Analysis
Steps 3–4: Function mapping, process requirements, failure modes, effects and causes.
Module 8
Risk Analysis & Prioritization
Step 5: Severity, Occurrence, Detection, Action Priority and risk ranking exercises.
Module 9
Optimization & Risk Reduction
Step 6: Preventive and detective controls, corrective actions, improvement ownership and risk reduction planning.
Module 10
Results Documentation & Control Plan Integration
Step 7: Completing PFMEA worksheets, connecting findings to Control Plans and sustaining process improvements.
Practical activity: Develop a PFMEA for a selected manufacturing process.
Course Content
Meet Your Instructor
Mr. Balakrishnan is a Manufacturing Quality Consultant, Lead Auditor, and Corporate Trainer with 30+ years of industrial experience across automotive manufacturing, quality management, and operational excellence. He has held senior quality leadership roles with organizations including BorgWarner, Valeo, Sintex BAPL, and Nippon Thermostat, managing plant quality, supplier quality, new product quality, and continuous improvement initiatives. His expertise spans PFMEA/FMEA, AIAG Core Tools, IATF 16949, ISO management systems, 8D, Root Cause Analysis, 7 QC Tools, Lean, Kaizen, Poka-Yoke, rejection reduction, and process improvement.
Invite Only
This course is currently closed
This course includes:
- Lessons 3
- Topics 1
- Duration 2 Days
- Quizzes 2
- Language English
Share
Report
