AIAG & VDA

FMEA Handbook
April 4, 2019
 Agenda
• Current Development Status
• Project Objective
• Leveraging the new FMEA Handbook
• Examples of major changes and their benefits
• Q&A
 Current Development Status
• Final Draft in Approval Process
– AIAG QSC: April 2, 2019
– VDA QMA: May 8, 2019
– Both approvals required to release the document
• Release of Handbook – June 2019
– Launch events in Germany and U.S.
• Availability of Training – Q3 2019
– Each Association updating training courses
 AIAG VDA FMEA - Project Objective

Update to include:
Provide consistent - Best Practices
direction, guidance to - Improved Examples
all automotive suppliers - Functional Safety

4
 Importance of New Methods and Tools
• Effective FMEA risk identification - never been more critical
– Rapid growth in component/system interactions
– Increasingly specialized technologies
– No change in legal obligations of producers
• Effective FMEA includes:
– Cross-functional team contributions
– Carefully identified system boundaries
– Thorough documentation of risks and actions
 Leveraging the AIAG & VDA FMEA Handbook
• The Essential Link Between COQ and FMEA
– You will need FMEA to make sure COQ / COPQ
improvement targets are met;
– You will need COQ / COPQ actual performance on similar
products and processes to make sure the FMEA risk
evaluation of the new product and/or process is realistic;
– Not acceptable reduction in Cost of Poor Quality (COPQ)
means FMEA was not effective
 Examples of Major Changes and Benefits
• 7 Step Approach
• Supplemental FMEA – MSR
• New Severity, Occurrence, Detection Tables
• PFMEA Failure Analysis
• Action Priority (AP) Tables
More Structured Approach – Leverages Lessons Learned – Prevention Driven
 AIAG &VDA FMEA - 7 Step Approach

Seven Step Approach

System Analysis Failure Analysis and Risk Mitigation Risk Communication
1st Step 2nd Step 3rd Step 4th Step 5th Step 6th Step 7th Step
Planning &
Preparation Structure Analysis Function Analysis Failure Analysis Risk Analysis Optimization Results Documentation

Project Visualization of the Visualization of product or Establishment of the failure Assignment of existing Identification of the actions Communication of actions
identification analysis scope process functions chain and/or planned controls necessary to reduce risks taken to reduce risks
and rating of failures
Project plan: DFMEA: DFMEA: DFMEA: DFMEA & PFMEA: Assignment of The layout of the document
InTent, Timing, Structure tree or equivalent: Function tree/net, function Potential Failure Effects, Assignment of Prevention responsibilities and may be company specific. The
Team, Tasks, block diagram, boundaryApplies to DFMEA, Supplemental FMEA – MSR, and PFMEA
matrix parameter diagram Failure Modes, Failure Controls to the Failure deadlines for action content may include the
Tools (5T) diagram, digital model, (P-diagram) Causes for each product Causes implementation following:
physical parts function • Executive summary
• Scope of the FMEA
PFMEA: PFMEA: PFMEA: DFMEA & PFMEA: • A reference to the specific
Structure tree or equivalent: Function tree/net or Potential Failure Effects, Assignment of Detection S/O/D Rating Tables used in
process flow diagram equivalent process flow Failure Modes, Failure Controls to the Failure the analysis
diagram Causes for each process Causes and/or Failure • Action Priority
 Supplemental FMEA - MSR
• FMEA MSR = Monitoring and System Response
– Supplemental approach for Design FMEA
– Addresses Risk Analysis of “Mechatronic Systems”
• Not previously addressed in AIAG 4th Edition FMEA
– Describes linkages between Design FMEA and Functional Safety
(ISO 26262) concepts and analyses
– Unique Frequency (F) and Monitoring (M) Rating Tables
 New PFMEA Severity Table
Process General Evaluation Criteria Severity (S)

Blank until filled

Potential Failure Effects rated according to the criteria below. in by user

Corporate or
Impact to Ship-to Plant Impact to End User
S Effect Impact to Your Plant Product Line
(when known) (when known) Examples

AIAG 4th Edition AIAG & VDA FMEA Handbook

Issue with Severity 10/9 10 – Safe operation defects
“Without warning” – “with warning” 9 – Noncompliance with regulations
 New PFMEA Occurrence Table
Occurrence Potential (O) for the Process

Potential Failure Causes rated according to the criteria below. Consider Prevention
Controls when determining the best Occurrence estimate. Occurrence is a predictive
qualitative rating made at the time of evaluation and may not reflect the actual Blank until filled
occurrence. The occurrence rating number is a relative rating within the scope of the in by user
FMEA (process being evaluated). For Prevention Controls with multiple Occurrence
Ratings, use the rating that best reflects the robustness of the control.

Corporate or
Prediction of Failure
O Type of Control Prevention Controls Product Line
Cause Occurring
Examples

AIAG 4th Edition AIAG & VDA FMEA Handbook

Rating based on defects/thousand, Rating based on robustness of
set for high volume production rates prevention controls, can be applied to
any production rate
 New PFMEA Detection Table
Detection Potential (D) for the Validation of the Process Design

Blank until
Detection Controls rated according to the Detection Method Maturity and Opportunity for
filled in by
Detection. user

Corporate or
Ability to
D Detection Method Maturity Opportunity for Detection Product Line
Detect Examples

AIAG & VDA FMEA Handbook

AIAG 4th Edition
Rating based on “Maturity of Detection
Rating based on “Opportunity for
Method” and “Opportunity of Detection”
Detection” and “Likelihood of
More stringent ratings, requires control of
Detection” by Process Controls
rejected product to prevent outflow
Failure Analysis (Step 4) – Process FMEA
Addition of 4M
• For each Failure Mode (FM)
consider these categories as
sources of Failure Cause (FC)
– Man
– Machine
Failure Chain Model
– Material
– EnvironMent
 Action Priority (AP) Table
Action Priority (AP) for DFMEA and PFMEA

Action Priority is based on combinations of Severity, Occurrence, and Detection ratings in order to Blank until
prioritize actions for risk reduction. filled in by user

Prediction of ACTION
Effect S Failure Cause O Ability to Detect D PRIORITY Comments
Occurring (AP)

AIAG 4th Edition AIAG & VDA FMEA Handbook

RPN = S x O x D S, O, D considered at the same time, while weighting
All three weighted equally Severity highest, then Occurrence, then Detection
Determines Priority of Action = H, M, L
 Adoption / Deployment Timing
• Expect “rolling change” not immediate changeover
– No expectation for “rework” of existing FMEAs
– Handbook recommends utilizing for updates to “Family” FMEAs
• Possible sequence for transition
1. Allow several months for OEM and supplier training
2. Acceptance of new methods, rating tables, forms on supplier FMEAs
3. Then shift to requirement for new products or processes
• Expect timing for adoption / deployment from OEM’s to be
communicated at AIAG Quality Summit in October, 2019
Thank You!