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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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

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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)

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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 (Sev, Occ, Det) • Risk Ratings (Sev, Occ, Det)
• Evaluation of Action Priority • Evaluation of Action Priority

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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

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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

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DFMEA Occurrence Table

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DFMEA Occurrence Table (contd.)

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DFMEA Detection Table

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PFMEA Severity Table

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PFMEA Severity Table (contd.)

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PFMEA Occurrence Table

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PFMEA Detection Table

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PFMEA Detection Table (contd.)

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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

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FMEA Action Priority Table (contd)

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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

Classification Potential
Potential Potential
Severity

Cause(s)/
Failure Effect(s) of
Mechanism(s)
Mode Failure
of Failure

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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
Pote ntia l Potentia l Failure E a Ca use
Failure Mode Effe cts V s s(s)
s of
Failur
e

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Optimization

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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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Тhank you!

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