Failure Mode and Effects Analysis for Quality and Safety in Automotive

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Apply structured risk assessment techniques to identify potential failures early and strengthen product and process quality.

By HUKSA

Last updated May 19, 2026

This training program on Failure Mode and Effects Analysis is designed for quality professionals in the automotive sector. It addresses the challenge of identifying and mitigating product and process risks that impact vehicle safety, reliability, and regulatory compliance. Participants will gain the ability to apply Design and Process FMEA methodologies to anticipate failures and strengthen quality systems. The program uses real automotive case studies, risk assessment exercises, and structured problem-solving tools to ensure practical application.

Course Content

Lesson Content

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Importance of proactive risk management in automotive manufacturing

Overview of Failure Mode and Effects Analysis (FMEA) methodology

Role of FMEA in Advanced Product Quality Planning (APQP)

Relationship between FMEA, quality management systems, and product safety

Key terminology: failure mode, failure effects, root causes, control methods

Case example: Product recall caused by design risk oversight

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Purpose and scope of Design FMEA (DFMEA)

Identifying potential design failures in vehicle systems and components

Evaluating severity and impact on safety and performance

Defining preventive design controls and validation requirements

Practical example: DFMEA for braking or steering systems

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Understanding Process FMEA (PFMEA) in manufacturing operations

Identifying process-related failure modes across production stages

Linking PFMEA with control plans and manufacturing quality controls

Risk evaluation using severity, occurrence, and detection scoring

Case example: PFMEA in assembly line operations

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Risk Priority Number methodology and prioritization logic

Identifying high-risk failure modes requiring corrective action

Designing preventive and detection controls to mitigate risks

Integrating corrective actions with production and design teams

Activity: Prioritizing risks in a sample automotive component process

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Alignment with IATF 16949 quality management framework

Linking FMEA outputs to control plans and production monitoring

Coordination between engineering, quality, and supplier teams

Ensuring traceability and documentation for regulatory compliance

Case study: Managing supplier-related quality risks

Lesson Content

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Using root cause analysis tools alongside FMEA

Incorporating lessons learned into updated FMEA documentation

Monitoring field failures and updating risk assessments

Digital tools for FMEA management and collaboration

Simulation: Conducting an end-to-end FMEA exercise for an automotive subsystem

Meet Your Instructor

Deep-domain, High Precision L&D - delivered directly by Renowned Industry Practitioners HUKSA

244 Course

165 Student

Offered by Huksa, this L&D program is led by elite industry veterans—CXOs and Functional Heads with 25+ years of deep-domain expertise. You have the flexibility to customize the curriculum, select your preferred expert, and align the program to your organization’s specific objectives. Connect with the Huksa team to explore our array of top-tier trainers available for this course!