VDA FMEA Overview

ASQ Section 1302 January 2020

Agenda

Why VDA FMEA was needed?

Key Differences from AIAG FMEA
7-Step VDA FMEA Process
Exercise
Q&A

2
Failure Modes and Effects Analysis
❑What is FMEA? A tool for proactively identifying how a
product, process or system can fail (Risks) – then prioritize
actions to reduce risks
❑Developed by NASA – adopted by the Automotive Ind.
❑Proactive > to be used early in the product or process
development > design out or control potential failure causes
❑Living > should be reviewed regularly – drive continuous
improvement
❑ PFMEA – Process FMEA – emphasizes lowering risk by error-
proofing process steps (risk reduction)
 Why was VDA FMEA needed?
Business objectives that support VDA FMEA
1. Increasing quality, reliability, manufacturability and safety of
Automotive products – driverless vehicles
2. Ensures the linkage, interface and alignment of requirements
to internal and external customers and suppliers
3. Building a knowledge base in the company – Lessons Learned
4. Ensures compliance with regulations and customer
requirements - IATF

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 AIAG & VDA Combined Methodologies

13-Step Process

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Changes with VDA FMEA (compared to AIAG)
❑ RPN is replaced with Action Priority level (High, Medium or
Low) for prioritizing risk reduction/improvement actions
❑ Greater emphasis on understanding function, and effect on
critical characteristics at each process
❑ Focus on prevention controls (error proofing)
❑ Columns in former FMEA format are moved to new locations
for greater emphasis
❑ 7-Step approach replaces FMEA 4th Edition 13-step approach
VDA FMEA 7-Step Process

7 Results Risk Communication

4 Failure Analysis Documentation

6 Optimization
5 Risk Analysis
Failure Analysis & Risk
Mitigation

3 Function Analysis
2 Structure Analysis System Analysis
1 Planning & Preparation

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VDA PFMEA Expectations
❑Clearly described potential failure modes in technically
precise specific terms (use x-functional team with SMEs)
❑Consequences of failure modes are accurately described
❑Failure causes are realistic and reasonable
❑Not Considered:
❑Extreme events are not considered
❑Failures resulting from intended misuse
❑Completeness:
❑Foreseeable potential failures are not concealed

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 VDA FMEA Overview

Step 1 – Planning and Preparation

– Process identification or product/process name
– Document number
– Individual and/or team responsibility for the FMEA update
– Revision level & date and original FMEA date

– Tier 1 & 2 suppliers often list production/platform info

9
2nd Step: Structural Analysis
❑Identifies and breaks down manufacturing process into Process items,
Process Steps and Process work elements
❑Tools include tree diagram (below) or block diagram
❑Use 4Ms to determine work element (Man, Machine, Material, Method)
 3rd Step: Function Analysis Process Item
❑Describes what the process item or process step is intended to do Control Factors

❑Identify all the functions performed at the process step and how
this function relates to: Inputs Process Outputs
1) The next higher levels
2) Impact on product characteristics Noise Factors
 4th Step: Failure Analysis
❑ Identify how the focus element process can go wrong
(Failure Modes), effects on product and process (failure
effects), severity of the effects and causes impacting:
1. End-product performance (Product Effect)
2. Downstream process quality/efficiency
3. Product Characteristics
 5th Step: Risk Analysis
❑ Describe/rate Severity(S) of Effects, the effectiveness of current
process prevention and detection controls, identified in step 4, and
calculates the Action Priority number
❑Highlight Special Characteristics – Customer req. or from D/PFMEA
 6th Step: Optimization
❑ Prioritize high risk failure modes and define corrective actions to reduce risks
with details action plans
❑Once actions are complete re-assess the the Severity, Occurrence and
Detection ratings
7th Step: Results Documentation
❑Confirm effectiveness and document tasks completed
and summarize the results of actions identified based on
PFMEA analysis
❑Management of the improvement actions
❑Communicate results and conclusions from analysis
within organization, customers and suppliers
 FMEA 4th Edition Method vs VDA FMEA
STRUCTURE ANALYSIS (Step 2) FUNCTION ANALYSIS (Step 3) FAILURE ANALYSIS (Step 4)
2. Function of the Process 1. Failure Effects

Severity (S) of
1. Function of the Process
1. Process Item System, 2. Process Step Station Step and Product 3. Function of the Process (FE) to the Next
3. Process Work Element Item, Function of System, 2. Failure Mode (FM) 3. Failure Cause (FC) of

FE
Subsystem, Part Element No. and Name of Focus Characteristic Work Element and Higher Level
4M Type Subsystem, Part Element Focus Element the Work Element
or Name of Process Element (Quantitative value is Process Characteristic Element and/or
or Process
optional) End User

AIAG 4th Ed. FMEA Format

Item

RISK ANALYSIS (Step 5) OPTIMIZATION (Step 6)

Occurrence (O) of

Occurrence (O) of
Severity (S) of FE
Detection (D) of

Detection (D) of
Characteristics
Action Priority

Action Priority
Filter Code
(Optional)
Target
Special
FC/FM

FC/FM
Prevention Controls Detection Controls (DC) Responsible Action Taken with Completion
FE

FE
(PC) of FC of FC of FM Completion Status Remarks
Person's Name Pointer to Evidence Date
Date

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 FMEA Overview
Rate Severity –Rate
the most serious
Failure Effect for a
given Failure Mode

Severity 9 or 10
Ranking is reserved
for vehicle safety
functions or
compliance

17
 PFMEA Occurrence Rating Guidelines
•Based on history
(customer complaints,
internal scrap, or
rework)
•Be conservative and
consistent in rating
Copied from FMEA manual 3rd Ed.
selections
•One table is used throughout local plant
•Supporting rational are documented
•Changes have been approved by local
customer management office

18
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VDA FMEA Detection Rankings

Review each column and to

determine best fit related
to controls ability to detect
either:
1) Failure Cause (FC)
2) Failure Mode (FM)

Column on the right can be

used for plant examples –
helps to drive consistency
 RISK ANALYSIS (Step 5)

Occurrence (O) of
Severity (S) of FE

Detection (D) of
❑ Using the S, O, and D ratings the next

Action Priority
FC/FM
FE
objective is the identify the Action
Priority level
❑ VDA FMEA software can do this EX 1 7 2 6 M
automatically
❑ Going left to right S>O>D in the AP EX 2 8 2 8 M
table on the next slide check for the
appropriate AP level EX 3 3 3 2 L

EX 4 5 4 5 L
❑See exercise values to the right
EX 5 8 4 7 H

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 EX5
EX3

EX1

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VDA FMEA Action Priority Rules
- (H) Highest Priority for action
- The team must either identify an appropriate action to improve
prevention and/or Detection controls or justify and document why the
current controls are adequate
- (M) Medium priority for action
- The team should identify appropriate actions to improve prevention
and/or detection controls, or, at company discretion, justify and
document why controls are adequate
- (L) Low priority for action
- Team could identify actions to improve prevention and detection
control
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Optimization (Step 6)
❑ Action Status Options:

❑ Action order of effectiveness:

❑ Process modifications to eliminate or mitigate Failure Effect (FE)
❑ Process modifications to reduce the Occurrence of Failure Cause (FC)
❑ Increase the Detection ability for the Failure Cause (FC) or Failure
Mode (FM)
Note: With any process modification, all impacted process steps are
evaluated again
 VDA FMEA 7-Step Approach - Example
SYSTEM ANALYSIS FAILURE ANALYSIS & RISK MITIGATION RISK COMMUNICATION

1st Step: PLANNING AND PREPARATION

❑Project Identification
❑Project Planning: 5T’s – InTent, Timing, Team, Task and Tools
❑Boundaries: What is included and excluded from the process?

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PLANNING AND PREPARATION
Example: A critical Automotive customer sent you and RFQ
to supply stainless steel for a new catalytic converter -
details below:
❑Two components: 1) Heat Shield (2-piece) and 2) Body (2
piece Upper & Lower)
❑Heat Shield: .6mm thick 409 stainless steel
❑Body: .8 mm thick 409 stainless steel
❑ Stamped (deep draw) shape and shear to shape >
assemble > resistance welded
*Assume stainless steel is a common product for your plant,
but this is a new grade (never before produced)
 Boundary Diagram
From Assy customer

STRUCTURE ANALYSIS (Step 2)

1. Process Item System,
2. Process Step Station No. and
Subsystem, Part Element or 3. Process Work Element 4M Type
Name of Focus Element
Name of Process

(Op10)Place lower body and

flanges in weld fixture Operator: Fixture: Materials
Core & Heat Shield (Op20) Weld lower body to
Operator: Machine: Method
flanges
Assembly
(Op40) Assemble core elements Operator: Method:
(Op60) Weld upper body to
flanges and lower body Operator: Machine: Method
...

From Process From Process

Flow Routing

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 OEM Assembles
VDA FMEA Structure Analysis Exhaust in Vehicle
Exhaust pipe
Visualizing Shipping Assy and Test
Assemble HS &
processing steps is Pressure Test
beneficial in Assemble Core
Weld & Test
STRUCTURE ANALYSIS (Step 2)
1. Process Item
2. Process Step Station
assessing structure Stamp & Shear
System, Subsystem,
Part Element or Name
of Process
No. and Name of Focus
Element
3. Process Work Element 4M
Type

risks and necessary Body & HS Stamp Lower

Body
(10)Setup coil
guides
Method:
Mat’l: Edge Variation
controls Coil Slitting (20) Set
progression
Machine: Method:
Man:
Cold Mill (30) Set draw Machine: Mat’l: Lot to
depth Lot Formability
Hot Mill (40) FAI Measurement:
...
Casting

LMF

Scrap Loading

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Function Analysis - Parameter Diagram
❑ Control Factors = System design parameters that engineering can change

Control Factors

Noise Factors
❑ Noise Factors = things that can influence the design that are not under
direct control of the engineer
❑Error States are any kind of inherent loss of energy transfer or other
undesirable system outputs
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Function Analysis - Parameter Diagram
❑ Control Factors- Mechanical and Chemical>>

Control Factors

Class exercise:
List Noise Factors
that could
Noise Factors
influence function
❑ Noise Factors –Performance Change Over Time, Extreme performance?
Environments, Piece to Piece variation, Customer Usage,
System Interactions

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 Function Analysis
❑Capture product and process functions for your processes
Process Functions:
❑A Function Analysis Structure Tree can help -one process focus element at a time Operator: Setup
2. Function of the Process
weld fixture, welder
1. Function of the Process
Item, Function of System,
Step and Product 3. Function of the Process and tooling and
Characteristic Work Element and Process
Subsystem, Part Element
(Quantitative value is Characteristic
parameters
or Process
optional)
(30) Position/align lower Op(60) Weld
Ensure proper alignment Operator:
body and flanges for core
for welding process upper body to
Assemble flanges,
assy procerss CC Assembly Place core sub-assy
(40) Weld lower body to Create structural and gas lower core assy.
and upper body in
body, core flanges barrier seal to lower
Process Function:
(50) Position core elements Place and align core Process Function: weld fixture
elements. Weld Assembly
for flow (no gases bypass) elements Create structural weld
for structural and ...
convertor core
(60) Weld upper body to Create structural and gas
(to flanges and lower Weld Robot: Weld
gas flow function and weld
flanges and lower body to
barrier seal between body assy) upper body to
prevent gas bypass or
escape upper body and lower Welded gas barrier seal flanges

From Structure From SA What does it do? How?

Weld Robot:
Analysis Step Routing step Welds upper and
Function Analysis Structure Tree lower flanges
 OEM Assembles
Function Analysis Exhaust in Vehicle
Exhaust pipe
Shipping Assy and Test
Identifying Functions Assemble HS &
requires knowledge of Pressure Test
2. Function of the Process
Assemble Core 1. Function of the Process
Step and Product 3. Function of the Process
transformative processes Weld & Test Item, Function of System,
Subsystem, Part Element
Characteristic
(Quantitative value is
Work Element and Process
Characteristic
or Process
in your plant Stamp & Shear optional)
Position/align lower body
Ensure proper alignment
Body & HS and flanges for core assy
procerss for welding process
Assemble flanges, Create structural and gas
Weld lower body to flanges
Coil Slitting body, core barrier seal to lower
Position core elements for Place and align core
elements. Weld flow (no gases bypass) elements
Cold Mill for structural and ...
gas flow function Weld upper body to flanges Create structural and gas
and lower body to prevent barrier seal between
Hot Mill Cross functional Address any gas bypass or escape upper body and lower

process
Casting teams identify characteristics
LMF
internal process (temp, pressures
etc.)
Functions
Scrap Loading

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 Function Analysis
❑ Function of Process identified in Structure Analysis is described in Process Function column
❑ The function or transforming action from the focus element is describe in the function of process step column
❑ The function of the process work element is described in the function of the Process work column
STRUCTURE ANALYSIS (Step 2) FUNCTION ANALYSIS (Step 3)
1)Process Item System, Process Step Station No. 1) Function of the Process Item, 2) Function of the Process Step 3) Function of the Process
Process Work Element 4M
Subsystem, Part Element and Name of Focus Function of System, Subsystem, and Product Characteristic Work Element and Process
Type
or Name of Process Element Part Element or Process (Quantitative value is optional) Characteristic
Receiving material (10) Receiving Inspection Material: (not meeting Ensure received material Validate material is correct per Ensure only conforming
spec)(damage)(assess coil identification and adherence to requirements material gets into production
runability and surface) specification (chemistry,
mechanicals, dimensional, safety
and appearance)
Slitting coil (20)Slitting Process Setup Machine: Slitter Slit full width coil to width Set payoff, guides slitting blades to Slitter: Edge guides set, blade
specification achieve customer width and edge quality/edge burr confirmed,
quality and meet efficient rate no damage confirmed,
(20)Slitting Process Setup Machine: Payoff Position incoming coil and set Payoff: Supplied coil set,
loop/tension requirements for controls on-line with press
efficient slitter operation controls, loop limit controls
set (to ensure correct tension
to slitter)
(20)Slitting Process Setup Machine: Takeup Set slitter pit loop limits and take- Takeup: set take-up
up parameters for efficient parameters and ensure
operator controls are
(20)Slitting Process Setup Man: Set and confirm safety rails /guards Ensure operator is safe form
are in place and functioning sharp edges and pinch points
(30) Slit coil to width Machine: Slitter slit coil - maintaining dimensions, Through out run; Slit width
edge quality and appearance are consistent and meets spec ,
met through out slitting run Edge quality consistent,
appearance quality meets
customer requirements
(40) Complete slitter run/ Machine: Takeup Ensure run finishes and coil is Banding to prevent lose of
band banded containment in shipment
 Failure Analysis (Step 4)
1. Identify FUNCTION ANALYSIS (Step 3) FAILURE ANALYSIS (Step 4)
potential Failure

Severity (S)
3. Function of the Process Work
1. Failure Effects (FE) 1
Modes (FMs) to the Next Higher 2. Failure Mode (FM) 3. Failure Cause (FC) of

of FE
Element and Process
Level Element Focus Element the Work Element
Characteristic
and/or End User
2. Determine Ensure only conforming material gets Damage to machines, Material incorrectly Wrong material type or gauge
Failure Effects into production tooling, Shipping N/C 6 identified gets to production
material to customer 2
(FE) )- at that Slitter: Edge guides set, blade Excessive burr on coil Dull slitter blade Slitting blade used beyound
process step, quality/edge burr confirmed, no edges (safety of
8
epected PM
damage confirmed, operators) (potential to
next hire level damage equipment 3
and/or end user Payoff: Supplied coil set, controls on- Downtime, frequent Slitter payoff not set-up improper Payoff setup
line with press controls, loop limit stops, inefficient slitter properly
controls set (to ensure correct tension operation 3
3. Brainstorm to slitter)
Failure Causes Takeup: set take-up parameters and Unable to ship coil. Take Up coiler - loosely Improper take-up parameters
5
(FC) ensure controls are in auto Rework or scrap rapped
Ensure operator is safe form sharp Operator (non-life Guarding not correctly set Guarding not set and
9
edges and pinch points Opposites of the
threatening) injury convimfed
Rank Severity (S) Through out run; Slit width consistent Stamping customer Slit width of coil varies Edge guide not properly set or
process function
during Risk Analysis and meets spec , Edge quality unable to run product, (OOS) during run hydraulic cylinder fails
consistent, appearance quality meets work elements 5
customer requirements
become FMs.
Coil banding is placed and properly Loss of coil containment Banding fails to contain slit Incorrect placement or crimp
9
secured coil is not suffucient
 Risk Analysis(Step 5)
FAILURE ANALYSIS (Step 4) RISK ANALYSIS (Step 5)

Occurrence (O) of
Severity (S) of FE

Detection (D) of

Characteristics
Action Priority

Filter Code
(Optional)
Special
FC/FM
2. Failure Mode (FM) Focus 3. Failure Cause (FC) of the Prevention Controls (PC) of Detection Controls (DC) of

FE
Element Work Element FC FC of FM

Material incorrectly Wrong material type or Lot information 1 Certificates of Analysis

2
identified gauge gets to barcoded from suppliers, Barcodes/
6 production 2 scanners used by Material 6 L
handlers to select material
3 4 from stock 5 6
Dull slitter blade Slitting blade used Blade PMs, Blade force End-of-coil inspection
8 beyond expected PM monitoring and alarm 2 8 M

Slitter payoff not set-up Improper Payoff setup Verification inspection by

properly Work Instructions, 2nd setup operator,
3 3 2 L
Checklists checklist

Take Up coiler - loosely Improper take-up Take-up parameters Checklist, First article,
5 rapped parameters saved - automatically 4 periodic check 5 L
loaded
Guarding not correctly Guarding not set and Training, sensor linked Visual, 2nd operator
8 set convimfed to controller (auto-off) 4 verifiction 7 H
 Risk Analysis (Step 5)
FAILURE ANALYSIS (Step 4)
Severity (S) of FE
1. Failure Effects (FE) to
the Next Higher Level
Element and/or End
User
Damage to machines,
tooling(7) Shipping N/C
material to customer(5)
Excessive burr on coil edges
(safety of operators)(8),
damage equipment(7)
Downtime(3), frequent
stops(3), inefficient slitter
operation(2)
Unable to ship coil-delay
shipment (5). Rework or
scrap(4)
Operator (non-life
threatening) injury
RISK ANALYSIS (Step 5)
Occurrence (O) of
Detection (D) of
Characteristics
Action Priority
Filter Code
(Optional)
Special
FC/FM
2. Failure Mode (FM) 3. Failure Cause (FC) of Prevention Controls Detection Controls (DC)
FE
Focus Element the Work Element (PC) of FC of FC of FM
Material incorrectly Wrong material type or Lot information 4 Certificates of Analysis 5 6
identified gauge gets to production barcoded from suppliers, Barcodes/
7 2 scanners used by Material 6 L
handlers to select material
from stock
Dull slitter blade Slitting blade used beyond Blade PMs, Blade force End-of-coil inspection
expected PM time monitoring(analytics)
8 2 8 M
Slitter payoff not set-up Improper Payoff setup Verification inspection by
properly 2nd setup operator,
3 None 3 2 L
checklist
Take Up coiler - loosely Improper take-up Take-up parameters Checklist, First article,
5 rapped parameters saved - automatically 4 periodic check 5 L
loaded
Guarding not correctly set Guarding not set and Training, sensor linked Visual, 2nd operator
8 confirmed to controller (auto-off) 4 verifiction 7 H
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7 Step Approach

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FMEA – MSR (VDA FMEA-Section 4)

Not directly
applicable for
base materials

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 Questions?

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Contact Info

BGengenbach@southeast.edu
(402)405-4980

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