Industry Forum

AS13100_RM13004 Defect Prevention Quality Tools to Support APQP & PPAP (Including FMEA and Control Plan)

Course overview: 

This course replaces AS13004 PFMEA & Control Plan.

This course covers FMEA and Control Plan requirements for AS13100 and AESQ Reference Manual RM13004 - Defect Prevention Quality Tools to support APQP and PPAP.  This course outlines the competitive advantages of effective Design and Process FMEA's along with the benefits of value-added controls within the control plan.

FMEA is an analytical method to ensure potential problems have been considered, assessed for risk, and actioned as part of product and process design.  It provides a record of an organisation's collective knowledge about its products and processes.  The intent of the control plan is to document and provide value added controls in support of the PFMEA process.  Implementation of an effective DFMEA, PFMEA and control plan form key foundation activities in support of the zero-defect goal.

Who should attend:  

This course is designed for Process Design Practitioners, Process Improvement Teams, Implementation Teams, Internal Auditors and others involved in the implementation or auditing of Process Failure Modes and Effects Analysis and Control Plans.


Upon completion of the course, you will receive an Industry Forum AS13100_RM13004 Defect Prevention Quality Tools to Support APQP & PPAP (Including FMEA and Control Plan) Certificate

Benefits and Learning Objectives:  

FMEA is used to support the introduction of new products and processes as well as supporting changes to existing products and processes.  It supports the goal of zero defects, defect prevention and the reduction of variation and waste.  Companies that apply DFMEA, PFMEA and Control Plans will see improved product conformity, better delivery performance and reduced cost of non-quality. 

Delegates will become competent in understanding the requirements of DFMEA and creating and analysing Process FMEA's / Control Plans at "Practitioner" level and will develop the capability to apply the methods to implement Failure Mode and Effect Analysis and Control Plans within their organisation.

Topics covered: 

FMEA General

  • System of defect prevention tools
  • Purpose and history of FMEA
  • Introduction to scope of AESQ RM13004
  • Risk and types of risk management
  • FMEA considerations and application
  • Cross functional teams
  • Define the customer FMEA steps and recommend actions
  • FMEA pitfalls
  • FMEA types

Design FMEA

  • Purpose and history of FMEA
  • Design FMEA thinking
  • Start points - boundary diagram
  • Function, failure modes, effects
  • Classification, causes and prevention
  • Key characteristics and critical characteristics
  • Severity, occurrence, detection and RPN
  • Detection and mistake proofing
  • Recommend actions and review

Process FMEA

  • AESQ RM13004 Requirements for PFMEA
  • Process FMEA start points
  • Process flow diagram scope and levels of detail
  • PFMEA essentials
  • PFMEA operation, function, failure mode and effect
  • Causes, prevention, value added prevention
  • Process mistake proofing
  • PFMEA severity, occurrence, detection and RPN
  • Recommended actions and review
  • Different PFMEA types - e.g. assembly
  • Different approaches to creating and maintaining
  • PFMEA Part specific
  • PFMEA and data duplication
  • Creating a reference PFMEA
  • Creating a part specific PFMEA - finite failure modes
  • PFMEA Review

Control Plan

  • Purpose, overview, AESQ RM13004 requirements
  • Control plan phases and linkages
  • Process flow diagram and the control plan
  • PFMEA prevention and detection overview and controls
  • Control plan structure and depth
  • Control plan development approach
  • Product and process characteristics 
  • Classification, requirements, evaluation, and sample size
  • Reaction planning and control plan review

Introduction to IF

We have been delivering significant and measurable performance improvements for leading global manufacturers for more than 25 years and believe there is no one size fits all approach to driving competitiveness across the industry. Toyota, Rolls Royce and Electrolux are among the brands who have tapped into our expertise to ensure they remain on top in their own fiercely competitive markets.

Why choose Industry Forum:   

Industry Forum helps major global manufacturers understand, optimise and improve both manufacturing capability and business performance.

An integrated team of consultants and practitioners – all seasoned expert engineers with multi-sector manufacturing experience – Industry Forum brings together a world-class combination of improvement competency, insight, process and best practice.

Spanning automotive, aerospace, consumer appliance, electronics and food sectors, for over 20 years Industry Forum has planned and delivered some of the world’s most consistent and successful transformations for business-critical manufacturing operations.

Our trainers are expert practitioners with hands-on industrial experience and highly developed communication skills.

They have a wealth of technical expertise and often provide on-site advice and coaching. During every course we will encourage collaboration and sharing of practical experiences, ensuring learning can be put into context and empowering delegates to apply their new skills successfully in their workplace as well as making sustainable improvements.

Training can be offered either through open courses or in-house to suit the customer requirements.

Course booking details:   

Leading Expertise
We don’t employ “trainers”, rather a team of experienced industry experts who are able to apply their knowledge to your business

Proven Capability
We have been helping organisations like yours for over 25 years to deliver and maintain sustainable improvement

Attainable Results
We know what’s possible and how to help you achieve it by utilising our tried and tested techniques for long term success

Robust Execution
We believe that training should be through a ‘learn by doing’ approach with coaching and mentoring wherever possible

No available dates for this course at present. Please fill in the form below to register your interest.

Contact Us