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1
New AIAG VDA FMEA Handbook
• AIAG FMEA-4 from the Automotive Industry Action Group
• VDA Volume 4 from the VDA (Verban der Automobilindustrie)

Latest :
• AIAG VDA Failure Mode and Effect Analysis (FMEA) Handbook.: June 2019, 1st Edition

+ + =

2
Why New AIAG VDA FMEA?
Suppliers providing products to both German and North America OEM's
were required to assess their products' failure modes and effects
differently, based on differences between the Severity, Occurrence, and
Detection rating tables in the VDA and AIAG FMEA Manuals.

This caused confusion and added complexity to the product development

and product improvement activities of the suppliers.

3
MAJOR CHANGES IN NEW AIAG
VDA FMEA

4
Major Changes (7 No’s) in New AIAG VDA FMEA
1. New 7 Steps
7. More approach defined
Collaboration
required with 2. RPN is
customers, replaced by
Suppliers and Action Priority
engineering teams (AP) – Low,
Medium & High

6. Scope & 3. Rating Chart

Results of FMEA revision for
needs to be global use by
summarized and automotive OEM
communicated & Suppliers

5. PFMEA : Failure
4. Use of 5 T
cause in 4 M-1 E
approach (InTent,
(Man, Machine,
Timing, Team,
Method, Material,
Task, Tool)
Environment)
5
7 Step Approach in AIAG VDA
FMEA

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New 7 Steps Approach - DFMEA

Step:1 Planning and Preparation

Step:2 Structure Analysis

Step:3 Functional Analysis

Step:4 Failure Analysis

Step:5 Risk Analysis

Step:6 Optimization

Step:7 Result Documentation

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New 7 Steps Approach 1st Step
1st Step: Project Planning & Preparation

Purpose: - To describe what product/processes to be included or excluded for

review in FMEA project.

Objective:

• FMEA project plan, such as important dates, FMEA responsible

persons, potential team members, project timelines, etc.
• Use 5 T approach (Team, Timings, Intent, Tool, Task)
• Define the boundaries of analysis (What to included/excluded)

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New 7 Steps Approach_ 1st Step Continue…….
Explanation of 5T’s Methodology:

5T’s Methodology in AIAG VDA FMEA

FMEA Team – Who needs to be on the team?

FMEA Timing – When is this due?

FMEA In Tent – Why are we here?

FMEA Tool – How do we conduct the analysis?

FMEA Task – What work needs to be done?

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New 7 Steps Approach_ 1st Step Continue…….
Explanation of 5T’s Methodology: Following Below table to be filled while
planning and Preparing FMEA Approach

Company Name Subject FMEA No:

FMEA Start Process

Plant Location
Date: Responsibility

FMEA Rev. Confidentiality

Customer Name
Date Level:

Model/ Year/
Core Team
Platform

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New 7 Steps Approach_ 2nd Step
2nd Step: Structure Analysis
The Structure Analysis transfers the information gathered in the scoping step to
visualize the relationships and interactions between the design or process elements.

The structure analysis is the basis for the next step (function analysis)

System Subsystem Product Component

Vehicle Brake System Caliper Brake Pad
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New 7 Steps Approach_ 2nd Step Continue……..
Visualization of the structure analysis
Boundary Diagram

12
New 7 Steps Approach_ 3rd Step
3rd Step: Function Analysis

A P-Diagram (Parameter Diagram) is a useful

tool used to determine and document
inputs and intended outputs for the item or
process under review, along with unintended
outputs (sometimes called error states), noise
factors, and control factors.

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New 7 Steps Approach_ 3rd Step
3rd Step: Function Analysis

P-diagram (parameter diagram)

14
New 7 Steps Approach_ 2nd Steps Continue……..
Visualization of the Structure Analysis

Structure Tree -
Process

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New 7 Steps Approach_ 3rd Step
3rd Step: Function Analysis
In this step the functionality of the product or processes are ensured by allocating a
description of the activities, purposes or tasks intended for the product performance.

System Product Component

Subsystem
Brake Pad
Vehicle Brake System Caliper
Transfer
Safe Stop Provide Vehicle Convert fluid Pressure friction to the
Passengers Deceleration to Clamp Force rotor
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New 7 Steps Approach_ 4th Step
4th Step: Failure Analysis
• Step # 4 is to identify failure causes, modes, and effects, and show their relationships to
enable risk assessment.

System Subsystem Product Component

Vehicle Brake System Caliper Brake Pad
Convert fluid pressure to Transfer friction to the
Safe Stop Provide Vehicle clamp force rotor
Passengers Deceleration •Caliper failed to convert fluid •Inner brake pad width
Unable to safe stop Unable to decelerate vehicle pressure to clamp force . designed too thin.
passengers Delayed deceleration •Reduced conversion of •Excessive friction
Rapid deceleration pressure to clamp force transferred
17 to the rotor.
New 7 Steps Approach_ 4th Step
Failure Effect: - It is related to function of process item. These are described in term of
what the customer might notice or experience.
Effect to be describe in three categories
▪ Internal failure effect,
▪ Ship to plant effect,
▪ End User effect
Failure Mode: - It is manner in which the process could cause the product not to deliver or
provide intended function.
Failure mode can be made through a review of past things gone wrong, reject or scrap reports, and
group brainstorming.

Failure Cause:- It is indication of why a failure mode could occur. The consciences of failure
cause is failure mode.
Why writing failure cause-We may include classic Ishikawa’s 4M- Man, Machine/Equipment,
Material (Indirect), Environment.

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New 7 Steps Approach_ 4th Step
Visualization of the failure analysis

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New 7 Steps Approach_ 5th Step
5th Step: Risk Analysis
Purpose: - Risk analysis purpose is to estimate risk by evaluating severity,
Occurrence & Detection in order to prioritize the need for action.

Objective: - To assign prevention control for failure causes, assign detection control
to failure cause/modes. Assign rating of severity, occurrence and detection control
for each failure chain. Evaluation of Action Priority (AP).

RISK ANALYSIS

Detection (D) of
Occurrence (O)

special feature

Filter code
(Optional)
FC/FM
of FC

AP
Current Prevention Controls Current Detection Controls

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New 7 Steps Approach_ 5th Step
5th Step: Risk Analysis
Prevention Control: - Process planning to minimize the possibility of failure occurrence.
These prevention control eliminates the failure cause & reduce its rate of occurrence.
Examples : - Poka Yoke- Subsequent part cannot be made, Equipment, maintenance, Work
Instructions, etc.

Detection Control: - Detection control detect the existence of failure cause & failure
mode, either by automatic or by manual method, before the item leaves the process
or reach to next station.

Examples:- Visual Inspection, Optical inspection by camera/Limit Samples, Vernier

caliper inspection, random inspection, etc.

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New 7 Steps Approach_ 5th Step
5th Step: Risk Analysis
Risk evaluation: - Each failure mode, failure cause & failure effect relationship is assessed for
its independent risk. Evaluation is done over three rating criteria.

Severity (S): - Stand for severity of failure effect

Occurrence (O): - Stand for occurrence for failure cause.

Detection (D):- Stand for detection for failure mode.

Evaluation number is given from 1 to 10. Where 10 is highest risk contribution.
Severity is rating number associated with most serious effect for a given failure mode..

Note: - Evaluation of failure effect should be mutually agreed by the customer

& the organization
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New 7 Steps Approach_ 6th Step
6th Step: Optimization
Purpose: - Purpose of process optimization is to determine action to mitigate the risk
& access the effectiveness of those action.

Objective: - Primary objective of optimization is to develop action that reduce risk by

improving the process. Identification of the action necessary to reduce the risk also
Implementation and documentation of action taken. Checking effectiveness of action
taken before and after. Here action represent a commitment to take a specific,
measurable & achievable action.

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New 7 Steps Approach_ 6th Step
6th Step: Optimization
In process optimization we do process modification to eliminates failure effect,
reduce occurrence of failure cause (FC) & increase the detection ability for FC & FM.

OPTIMIZATION

Occurance (O)

Detection (D)
Severity (s)
Status: (Untouched,
Target
Prevention Detection Responsibile under consideration, in Action Taken with Completion

AP
Completion
Action Action Person progress, completed, Pointer to Evidence Date
on date
discarded)

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New 7 Steps Approach_ 7th Step
7th Step: Result Communication

Documentation & Communication of implemented

measures to reduce risks, assessment of the
effectiveness of the action taken

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D-FMEA
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 Design FMEA Format
STRUCTURE ANALYSIS FUNCTION ANALYSIS

3. Function of Component
2. System Element / 1. Function of System and 2. Function of System
3. Component Element Element and Requirement
1. System Interface Requirement or Intended Element and Intended
(Item/Interface) or Intended Output or
Output Performance Output
Characteristic

FAILURE ANALYSIS

(S) of FE
Severity
1. Failure Effects (FE) 2. Failure Mode (FM)
3. Failure Cause (FC)

RISK ANALYSIS

Occurance (O) of

Detection (D) of

special feature

Filter code
(Optional)
FC/FM

AP
FC
Current Prevention Controls Current Detection Controls

OPTIMIZATION

Occurance (O)
Status:

Detection (D)
Severity (s)
(Untouched, under
Action Taken with
Responsibile Target Completion consideration, in

AP
Prevention Action Detection Action Pointer to Completion Date
Person on date progress,
Evidence
completed,
discarded)

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 Example of DFMEA (1/2)
STRUCTURE ANALYSIS (STEP 2)

3. Next Lower level or Characteristic Type

1. Next Higher Level 2. Focus Element (Geometry, Material, Surface Finish, Coating,
etc.)
Window Lifter Commutation system Brush card base body

FUNCTION ANALYSIS (STEP 3)

1. Next Higher Level Function and 2. Focus Element Function and 3. Next Lower Level Function and
Requirement Requirement Requirement or Characteristic
Converts electrical energy into mechanical Commutation system transports the Brush card body transports forces between
energy acc to parameterization electrical current between coil pairs of spring and motor body to hold the brush
the electromagnetic converter. spring system in x, y, z position (support
commutating contact point)

FAILURE ANALYSIS (STEP 4)

(S) of FE
Severity

1. Failure Effects (FE) to Next Higher Level 3. FAILURE CAUSE (FC) of the Next Lower Element or
2. FAILURE MODE (FM) of the Focus Element
Element and/or Vechile End User Characteristic

Torque and rotating velocity of the window 6 Angle deviation by commutation system Brush card body bends in contact area of the carbon
lifter motor too slow intermittently connects the wrong coils (L1, L3 brush
and L2 instead of L1, L2 and L3)

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 Example of DFMEA (2/2)
RISK ANALYSIS (STEP 5) OPTIMIZATION (STEP 6)

Detection (D) of FC/FM

Filter Code (Optional)

Occurance (O) of FC Status:

Occurance (O)
(Untouched,

Detection (D)
Severity (s)
DFMEA AP
under Action
Current Current Target
Prevention Detection Responsibil consideratio Taken with Completion

AP
Prevention Detection Completion
Action Action e Person n, in Pointer to Date
Controls Controls Date
progress, Evidence
completed,
discarded)

Simulation of 2 Sample test: 2 L None Final Product Test DD.MM.YYY Planned

dynamic measuring the test: measuring Engineer Mr. Y
forces on elastic and the current Max Mueller
brush card plastic under worst
body acc. FEM deformation case conditions
8370 effects of acc. Test spec/
brush card MRJ1140
body acc. Test
spec. MRJ8/60

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Rating Criteria - DMFEA

Refer the Rating Criteria in a separate annexure for

Severity, Occurrence, Detection and Action Priority for
DFMEA
 FMEA Action Priority (AP)
Action Priority
Action Expectation
(AP)
The team must either identify an appropriate action to improve prevention and / or detection
High
controls or justify and document why current controls are adequate.

The team should identify appropriate actions to improve prevention and / or detection controls, or,
Medium
at the discretion of the company, justify and document why controls are adequate.

Low The team could identify actions to improve prevention or detection controls.
It is recommended that potential Severity 9-10 failure effects
with Action Priority High and Medium, at a minimum,
be reviewed by management including any actions that were taken.
This is not the prioritization of High, Medium, or Low risk.
It is the prioritization of the need for actions to reduce risk.

31
Design FMEA Format

32
 Case Study &
Brain Gym - Activity Time for
DFMEA

33
P-FMEA
34
New 7 Steps Approach - PFMEA

Step:1 Planning and Preparation

Step:2 Structure Analysis

Step:3 Functional Analysis

Step:4 Failure Analysis

Step:5 Risk Analysis

Step:6 Optimization

Step:7 Result Documentation

35
Fill in the blanks method
C Responsibility &
Item / Function / Potential S l Potential Cause(s) / O Current D R S O D R
Op / Potential Failure Current Controls Recommended Target Action(s)
Process Effect(s) of E a Mechanism(s) of C Controls E P E C E P Status
Ref # Mode Detection Action(s) Completion Taken
Description Failure V s Failure C Prevention T N V C T N
s Date

We used to fill FMEA from left to right during creation and change of the analysis
BEFORE

NOW
New manual & form sheet add structure to help drive team to a more complete analysis
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Failure Analysis - EMC

What
Failure Mode Failure Cause
happens?
Why?
Failure Effect

Focus Element

Failure Effect (FE) - What happens after a failure occurs?

Failure Mode (FM) - It’s a way or mode process might fail
Failure Cause (FC) - Reason for failure mode
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Before / Now Comparison

PFMEA

BEFORE NOW
4th Ed FMEA New AIAG-VDA FMEA
Item STRUCTURE ANALYSIS
/ Function / Process
Description
2. Process Step
1. Process
3. Work Element
(Process Step, Station No.
(Process Item, System,
and Name of the Focus (Process Work Element - 4M
Subsystem, Part Element or
Element) Type)
Name of the Process)

38
Before / Now Comparison

PFMEA
NOW
BEFORE New AIAG-VDA FMEA
4th Ed FMEA
FUNCTION ANALYSIS
Item
/ Function / Process
Description

1. Function of Process Item,

2. Function of Process Step, 3. Function of Work Element
System, Subsystem, Part
Station No. and Name of the (Process Work Element - 4M
Element or Name of the
Focus Element) Type)
Process)

39
Before / Now Comparison

DFMEA And PFMEA

BEFORE NOW
4th Ed FMEA New AIAG-VDA FMEA

FAILURE ANALYSIS
C

Severity (S) of
S l
Potential Failure Potential Effect(s) Potential Cause(s) /
E a
Mode of Failure Mechanism(s) of Failure

FE
V s 1. Failure Effects (FE) 2. Failure Mode (FM)
s 3. Failure Cause (FC)

40
Before / Now Comparison

DFMEA
BEFORE NOW
4th Ed FMEA New AIAG-VDA FMEA

C RISK ANALYSIS (STEP 5)

S l Potential Cause(s) / O Current D R
Current Controls
E a Mechanism(s) of C Controls E P

Detection (D) of FC/FM

Detection

Occurance (O) of FC
V s Failure C Prevention T N
s

DFMEA AP

(Optional)
Filtercode
Current Prevention
Current Detection Controls
Controls

NEW

41
Before / Now Comparison

PFMEA
BEFORE NOW
4th Ed FMEA New AIAG-VDA FMEA
C RISK ANALYSIS
S l Potential Cause(s) / O Current D R
Current Controls

Detection (D) of FC/FM

E a Mechanism(s) of C Controls E P

Occurance (O) of FC
Detection
V s Failure C Prevention T N

special feature

Filter code
(Optional)
s
Current Prevention Current Detection

AP
Controls Controls

NEW

Filter Code (Option) - The Filter Code column can be used to write any other information by
organization. It is totally optional. E.G – You can filter internal process or section wise process

42
Before / Now Comparison
DFMEA And PFMEA
BEFORE
4th Ed FMEA
Responsibility & S O D R
Recommended
Target Completion Action(s) Taken E C E P
Action(s)
Date V C T N

NOW NEW
New AIAG-VDA FMEA
OPTIMIZATION
Status:

Occurance (O)

Detection (D)
(Untouched,

Severity (s)
Target under Action Taken
Responsibile

AP
Prevention Action Detection Action Completion on consideration, in with Pointer to Completion Date
Person
date progress, Evidence
completed,
discarded)

NEW

43
Process FMEA Format
STRUCTURE ANALYSIS
2. System Element / Interface
1. System 3. Component Element (Item/Interface)

FUNCTION ANALYSIS

1. Function of System and Requirement or Intended 2. Function of System Element and Inteded 3. Function of Component Element and Requirement
Output Performance Output or Intended Output or Characteristic

FAILURE ANALYSIS

(S) of FE
Severity
1. Failure Effects (FE) 2. Failure Mode (FM)
3. Failure Cause (FC)

RISK ANALYSIS

Detection (D)
Occurance

Filter code
(Optional)
(O) of FC

of FC/FM

special
feature
AP
Current Prevention Controls Current Detection Controls

OPTIMIZATION

Occurance (O)

Detection (D)
Status: (Untouched,

Severity (s)
under consideration,
Target Completion Action Taken with

AP
Prevention Action Detection Action Responsibile Person in progress, Completion Date
on date Pointer to Evidence
completed,
discarded)

44
Example of PFMEA (1/2)
STRUCTURE ANALYSIS
2. System Element / Interface
1. System 3. Component Element (Item/Interface)
Electrical Motor Assy Line [OP30] Sintered Bearing Press-in Process Operator

FUNCTION ANALYSIS
1. Function of System and Requirement or Intended 2. Function of System Element and Inteded 3. Function of Component Element and
Output Performance Output Requirement or Intended Output or Characteristic
Your Plant Press in sintered bearing to achieve axial position in Operator press the button of machine for releasing
Assembly of shaft into pole housing assembly. pole housing to max gap per print. the press-in process when loading is completed
Ship to Plant
Assembly of motor to vehicle door without line
stoppage sort or containment.
End User
Window raises and lowers.

FAILURE ANALYSIS
y (S) of
Severit

FE

1. Failure Effects (FE) 2. Failure Mode (FM)

3. Failure Cause (FC)
Your Plant 8 Axial position of sintered bearing is not reached Machine stops before reaching final position
Clearance too small to assemble shaft
Ship to Plant
Assembly of motor to vehicle door is not
possible.
End User
Comfort closing time too long.

45
Example of PFMEA (2/2)

RISK ANALYSIS OPTIMIZATION

Detection (D) of FC/FM

Occurrence (O) of FC
Status:

Occurrence (O)
special feature
(Untouched,

Detection (D)
Severity (s)
Filter code
(Optional)
under
Current Target Action Taken
Current Detection Prevention Detection Responsible consideratio Completion

AP

AP
Prevention Completion with Pointer
Controls Action Action Person n, in Date
Controls on date to Evidence
progress,
completed,
discarded)

None 10 Lot Release Protocol 2 H Selected Selected Press Process DD.MM.YYYY Open DD.MM.YYYY 3 2 L
Objective (Effectivity press with with force Engineer Mr.
100%) position monitoring Paul Duncan
Visual Gauge
inspection of axial gap
control
of bearing to pole sensor
housing seat by
Operator
Detection indicator
OK/NOK
(RED/GREEN area)
100% check of motor
performance curve acc
spec MRKJ5038

46
Rating Table
Objective:

Each failure mode, cause and effect relationship (failure chain) is assessed
for its independent risk.

Evaluation numbers from 1 to 10 continue to be used for S, O, and D

respectively

• 10 stands for the highest risk contribution

• By examining these ratings individually and in combinations of the three

factors the need for risk-reducing actions may be prioritized as High,
Medium or Low.
Rating Table
Before

Severity:

The Severity rating (S) is a measure

associated with the most serious
failure effect for a given failure mode
of the function being evaluated. The
rating shall be used to identify
priorities relative to the scope of an
individual FMEA and is determined
without regard for occurrence or
detection.
PFMEA Rank Chart Severity (Extract)
Rank 10 – Safety
Rank 9 - Regulations
Manufacturing Effect Divided Into Further Two Columns.
Process General Evaluation Criteria Severity S
Failure Effects rated for Manufacturing, Assembly, and End User as shown in PFMEA
SEV Your Process Ownership The Next Process Ownership(s) End User (when known)
Your Plant (when known) Ship to Plant Customer

Failure may endanger operator (machine or assembly), Failure may endanger operator (machine or assembly), Affects safe operation of the vehicle and/or
10 Possible long term effects on health of production Possible long term effects on health of production other vehicles, the health of operator or
associates associates passenger(s) or road users or pedestrians.

9 Failure may result in in-plant regulatory noncompliance Failure may result in in-plant regulatory noncompliance Noncompliance with regulations.

Line shutdown greater than full production shift. Stop

Loss of essential vehicle function necessary
shipment possible. Field repair or replacement required
8 100% of product affected may have to be scrapped. for normal driving during expected service
(Assembly to End User other than for regulatory
life.
noncompliance.

… … … …

Defective product triggers no reaction plan. Additional

1 No discernible effect defective products not likely. Sort not required. No discernible effect.
Feedback to supplier not required.
Rating Criteria - PFMEA

Refer the Rating Criteria in a separate annexure for

Severity, Occurrence, Detection and Action Priority for
PFMEA
FMEA Action Priority (AP)
Action Priority
Action Expectation
(AP)
The team must either identify an appropriate action to improve prevention and / or detection
High
controls or justify and document why current controls are adequate.

The team should identify appropriate actions to improve prevention and / or detection controls, or, at
Medium
the discretion of the company, justify and document why controls are adequate.

Low The team could identify actions to improve prevention or detection controls.

It is recommended that potential Severity 9-10 failure effects with Action Priority High and Medium, at a minimum,
will be reviewed by management including any actions that were taken.

This is not the prioritization of High, Medium, or Low risk. It is the prioritization of the need for actions to reduce
risk.

51
Process FMEA Format

52
 Case Study &
Brain Gym - Activity Time for
PFMEA

53
Handling of existing FMEA
•Existing FMEAs conducted with an earlier version of the FMEA handbook may remain in
their original form for subsequent revisions.

•Optionally, the team may decide to transfer the data to the latest form and update the
FMEA in accordance with the latest FMEA procedure, in order to take advantage of
improvements associated with the latest FMEA procedure.

•FMEA that will be used as a starting point for new program applications
should be converted to comply with the new format.

•However, if the team determines that the new program is considered a minor change to
the existing product, they may decide to leave the FMEA in the existing format.

•New projects should follow this FMEA procedure if not otherwise defined unless company
procedure defines a different approach.
54
FMEA is a LIVE Document,
Keep it Alive !
Email – support@submastery.com ,
Website - https://submastery.com

55