Automotive QMS IATF 16949

Crux of the Core tool : A glimpse

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 Automotive QMS : IATF 16949 Crux from the core tool manuals FMEA

# Name of the manual Latest edition # Year Developed by

1 Failure Mode & Effects Analysis ( FMEA ) 1 2019 AIAG & VDA *
2 Statistical Process Control ( SPC ) 2 2005 AIAG

3 Measurement Systems Analysis ( MSA ) 4 2010 AIAG

4 Advanced Product Quality Planning & Control Plan methodology ( APQP & CP ) 2 2008 AIAG

5 Production Part Approval Process ( PPAP ) 4 2006 AIAG

* VDA : Verband Der Automobile Industry ( of West Germany )

FMEA

( Pg # 64 of the APQP manual )

( Pg # 78 of the APQP manual )

Important notes :
1. The above Checklists are from the 2nd edition of APQP & CP manual. ( not from the latest FMEA manual )
2. With suitable changes ( e.g. Action Priority, instead of RPN ), you may consider them as sample checklists for the new version of FMEA
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Only for the Training purpose Important note : Please ensure the latest editions of the manuals, before referring any information from this document
 Automotive QMS : IATF 16949 Crux from the core tool manuals FMEA

# Name of the manual Latest edition # Year Developed by

1 Failure Mode & Effects Analysis ( FMEA ) 1 2019 AIAG & VDA
2 Statistical Process Control ( SPC ) 2 2005 AIAG

3 Measurement Systems Analysis ( MSA ) 4 2010 AIAG

4 Advanced Product Quality Planning & Control Plan methodology ( APQP & CP ) 2 2008 AIAG

5 Production Part Approval Process ( PPAP ) 4 2006 AIAG

FMEA ( contd.. ) ( Pg # 54 of the manual )

Design FMEA : Potential Network & Chain analysis

D FMEA D FMEA D FMEA D FMEA Analysis level

Analysis level Failure Examples
at OEM at Level 1 at Level 2 at Level 3 examples

Passenger compartment Comfort closing time too long

Vehicle
FE
Window lifter system Moving speed of window glass too low
System
FM FE
Window lifter Motor Torque & rotating velocity of the window lifter motor
System element FC too low
FM FE
Communication System Communication system intermittently connects the wrong
System Sub-element coils ( L1, L3 & L2 instead of L1, L2 & L3 )
FC FM FE Focus Element
@
Component element Brush card body bends in contact area of the
FC FM Brush Card Base body carbon brush

Brush Card Base body Too low stiffness in carbon brush contact area
( Design ) Feature
characteristics FC Characteristics

Failure chains Failure network

FEs Failure Effect(s)

Figure 2.4-4 Failure Structure at different levels
FMs Failure Mode(s)
❑ To link Failure Causes(s) to a Failure Mode, the question should be “Why is the Failure Mode happening?”
FCs Failure Causes(s)
❑ To link Failure Effects to a Failure Mode, the question should be “What happens in the event of a Failure Mode?”

( Pg # 55 of the manual )

Figure 2.4-5 Example of Failure analysis Structure tree

Window lifter system

Indicative communication system

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Only for the Training purpose Important note : Please ensure the latest editions of the manuals, before referring any information from this document
 Automotive QMS : IATF 16949 Crux from the core tool manuals FMEA

# Name of the manual Latest edition # Year Developed by

1 Failure Mode & Effects Analysis ( FMEA ) 1 2019 AIAG & VDA
2 Statistical Process Control ( SPC ) 2 2005 AIAG

3 Measurement Systems Analysis ( MSA ) 4 2010 AIAG

4 Advanced Product Quality Planning & Control Plan methodology ( APQP & CP ) 2 2008 AIAG

5 Production Part Approval Process ( PPAP ) 4 2006 AIAG

* For P FMEA activity

FMEA ( contd.. ) ( Pg # 108 & 109 of the manual )

Process General Evaluation criteria severity ( S )

Blank until filled in by
Potential Failure Effects rated according to the criteria below.
user
Effect

Impact to Ship- to plant Impact to End User Corporate or product

S Impact to your plant
( When Known ) ( When Known ) Line examples
Affects safe operation of the vehicle
Failure may result in an acute health Failure may result in an acute health
and/or other vehicles, the health of driver
10 and/or safety risk for the and/or safety risk for the
or passenger(s) or road users or
High

manufacturing or assembly worker manufacturing or assembly worker

pedestrians.
Failure may result in in-plant regulatory Failure may result in in-plant regulatory
9 Noncompliance with regulations
noncompliance noncompliance
Line shutdown greater than full
production shift; stop shipment
100% of production run affected may possible; field repair or replacement
have to be scrapped. required ( Assembly to End user )
Loss of primary vehicle function necessary
Failure may result in in-plant regulatory other than for regulatory non
8 for normal driving during expected service
Moderately high

noncompliance or may have a chronic compliance. Failure may result in in-

health and/or safety risk for the
manufacturing or assembly worker
life.
plant regulatory noncompliance or may
have a chronic health and/or safety risk
for the manufacturing or assembly
worker

Product may have to be sorted and a
portion ( less than 100% ) scrapped;
7 deviation from primary process;
decreased line speed or added
manpower
Line shutdown from 1 hour up to full
production shift; stop shipment
possible; field repair or replacement
required ( Assembly to End user ) other
than for regulatory noncompliance.
Degradation of primary vehicle function
necessary for normal driving during
expected service life.

100% of production run may have to be

6 Line shutdown up to one hour Loss of secondary vehicle function.
reworked off line and accepted.
Moderately low

Less than 100% of product affected;

A portion of the production run may
strong possibility for additional Degradation of secondary vehicle
5 have to be reworked off line and
defective product; sort required; no line function.
accepted
shutdown.

100% of the production run may have to Defective product triggers significant
Very objectionable appearance, sound,
4 be reworked in – station before it is reaction plan; Additional defective
vibration, harshness, or haptics
processed products not likely; Sort not required.

A portion of the production run may Defective product triggers minor

Moderately objectionable appearance,
3 have to be reworked in – station before reaction plan. Additional defective
sound, vibration, harshness, or haptics.
it is processed products not likely; Sort not required.
Low

Defective product triggers no reaction

Slight inconvenience to process, plan; additional defective products not Slightly objectionable appearance, sound,
2
operation, or operator. likely; sort not required; requires vibration, harshness, or haptics.
feedback to supplier
Very
low

1 No discernible effect. No discernible effect or no effect No discernible effect.

* Note : This table has been aligned to Errata Version 2, June 2020

( Pg # 94 of the manual )

( Pg # 106 of the manual ) 4

( end of FMEA )
Only for the Training purpose Important note : Please ensure the latest editions of the manuals, before referring any information from this document
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