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

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.

What Will You Learn

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

Is This Course For You

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.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time


  • 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