Failure Modes and Effects
Analysis (FMEA)
New 7 Step Approach!
QSG Quarterly Meeting
October 25, 2019
Laura Halleck
laura.halleck@qualitysupportgroup.com
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Agenda
• FMEA Alignment of AIAG & VDA
• 7 Step Approach
• Revised Rating Tables
• Key Changes
• Transition Strategy
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FMEA Alignment of AIAG & VDA
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FMEA Alignment of AIAG & VDA
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FMEA Alignment of AIAG & VDA
• Automotive suppliers to both North American and German
OEMs were required to assess their failure modes and
effects differently
• Differences between the Severity, Occurrence, and Detection rating
tables in the AIAG and VDA FMEA Manuals
• Caused confusion and added complexity to product
development and process improvement activities
• Alignment was needed in order to create a common set of
requirements so suppliers can have a single FMEA business
process meeting needs and expectations of any of their
automotive customers
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7 Step Approach
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7 Step Approach
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Source: AIAG / VDA FMEA Handbook
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Step 1: Planning & Preparation
Five T’s Questions to Answer
InTent • Have all Core Team Members received training on FMEAs?
• Have all Core Team Members allocated time to fully participate?
Timing • What APQP Phase or VDA Maturity Level is the project in?
• What is the FMEA Start Date and Target Completion Date?
Team • Have the team members been assigned with clearly defined roles
and responsibilities (Leader, Facilitator, Champion, Core Team
Member, Extended Team Member)?
Task • Is the scope of the study clear?
• Has the documentation/reporting methodology been clarified?
• Will the FMEA Report be shared with customers?
• Will the FMEA results be audited?
Tools • Will a spreadsheet or specific software program be used to
document the results?
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Step 2: Structure Analysis
DFMEA PFMEA
• Identification of design • Identification of process
interfaces, interactions, steps and sub-steps
close clearance • Tools:
• Tools: • Structure tree
• Structure tree • Process flow diagram
• Block diagram
• Boundary diagram
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Step 3: Function Analysis
DFMEA PFMEA
• Association of • Association of
requirements to functions characteristics to functions
• Tools: • Tools:
• Function analysis tree • Function analysis tree
• Parameter diagram • Parameter diagram
Source: AIAG / VDA FMEA Handbook
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Step 4: Failure Analysis
DFMEA PFMEA
• Potential Failure Effects, • Potential Failure Effects,
Failure Modes, Failure Failure Modes, Failure
Causes for each product Causes for each process
function function
• Tools: • Tools:
• Parameter diagram • Fishbone diagram (4M)
Source: AIAG / VDA FMEA Handbook
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Step 5: Risk Analysis
DFMEA PFMEA
• Assignment of Prevention • Assignment of Prevention
Controls to Risk Causes Controls to Risk Causes
• Risk Ratings (Dev, Occ, Det) • Risk Ratings (Dev, Occ, Det)
• Evaluation of Action Priority • Evaluation of Action Priority
Source: AIAG / VDA FMEA Handbook
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Step 6: Optimization
DFMEA PFMEA
• Assignment of • Assignment of
responsibilities and due responsibilities and due
dates dates
• Implementation of actions • Implementation of actions
Source: AIAG / VDA FMEA Handbook
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Step 7: Results Documentation
• Communicate results and conclusions of the
analysis
• Within organization
• With customers and/or suppliers (as appropriate)
• Document actions taken including effectiveness
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Revised Rating Tables
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DFMEA Severity Table
Source: AIAG / VDA FMEA Handbook
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DFMEA Occurrence Table
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DFMEA Detection Table
Source: AIAG / VDA FMEA Handbook
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PFMEA Severity Table
Source: AIAG / VDA FMEA Handbook
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Source: AIAG / VDA FMEA Handbook
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PFMEA Occurrence Table
Source: AIAG / VDA FMEA Handbook
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PFMEA Detection Table
Source: AIAG / VDA FMEA Handbook
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Source: AIAG / VDA FMEA Handbook
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Action Priority
• High (H):
• Required to identify appropriate action to improve Prevention
and/or Detection Controls; OR justify and document why current
controls are adequate
• Priority Medium (M):
• Should identify appropriate actions to improve prevention and/or
detection controls; OR, at the discretion of management, justify and
document why current controls are adequate
• Priority Low (L):
• Could identify actions to improve prevention or detection controls
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FMEA Action Priority Table
Source: AIAG / VDA FMEA Handbook
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Source: AIAG / VDA FMEA Handbook
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Key Changes
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DFMEA Structure Analysis
AIAG 4th Ed FMEA New AIAG-VDA 1st Ed FMEA
Item &
Function
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DFMEA Function Analysis
AIAG 4th Ed FMEA New AIAG-VDA 1st Ed FMEA
Item &
Function
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DFMEA Failure Analysis
AIAG 4th Ed FMEA New AIAG-VDA 1st Ed FMEA
Potential
Classification
Potential Potential
Severity
Cause(s)/
Failure Effect(s) of
Mechanism(s)
Mode Failure
of Failure
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DFMEA Risk Analysis
Removed – special characteristic identification not required in DFMEA; can use
Filter Code column (optional)
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PFMEA Structure Analysis
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PFMEA Function Analysis
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PFMEA Failure Analysis
AIAG 4th Ed FMEA New AIAG-VDA 1st Ed FMEA
C
S l Potential
Potential Failure Mode Potential Failure Effects E a Causes(s)
V s of Failure
s
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PFMEA Risk Analysis
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DFMEA Optimization
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Transition Strategy
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Transition Strategy
(Automotive Suppliers)
• Existing FMEAs developed per the AIAG 4th Edition can
remain
• Plan the transition
• From current FMEA processes and methods to the new AIAG VDA
FMEA process and tools
• Use existing FMEAs for a starting point
• Consider: Minor or major change, New rating scales, Analytical
methods and format
• New projects
• Consider:
• Company leadership mandates, Customer Specific Requirements
Transition date and milestones
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Questions?
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