The AIAG-VDA FMEA Process and Approach

by Mary Rowzee published on August 12, 2020

AIAG-VDA FMEA Handbook has begun to gain popularity in the Global Automotive Industry in both US and European OEMs have started to require the use of the AIAG VDA FMEAs in their programs. Like the AIAG Guidebook 4th edition, the Handbook provides guidance, instruction, and illustrative examples of the requisite analytical techniques, the activities, and analyses historically involved in creating FMEAs have been formalized as discrete steps in the Handbook. The seven-step approach described in the Handbook guides the development of Design, Process, and Supplemental Monitoring and System Response FMEAs through the sequencing (and the iteration) of described activities.

The Seven-Step Approach: Fundamental Activities

  1. Planning and Preparation: Develop an FMEA Project Plan
  2. Structure Analysis: Depict the product or process to be analyzed using an appropriate graphical/visual method.
  3. Function Analysis: Identify the functions to be performed and the requirements or criteria by which their performance is evaluated, in Design and Process FMEA development.
  4. Failure Analysis: Identify Failure Modes, Effects of Failure, and Causes of Failure.
  5. Risk Analysis: Estimate the level of design or process risk by assigning Severity of Effect, Occurrence of the Cause, and Detection of the Cause of Failure.
  6. Optimization: Based on risk evaluation, determine which aspects of the Design and Process require risk-mitigating actions and define those actions.
  7. Results and Documentation: Summarize, highlight, communicate and document the findings, risk reductions and remaining residual product and process risk.

Omnex Inc. continues to incorporate innovations into FMEAs and most recently Omnex has developed a methodology for identifying and including Multi-point failures in the Design FMEA. Using this approach, the DFMEA would serve as a repository for potential faults and failures resulting from the simultaneous and sequential causes, in addition to the traditional, single causes. Additionally, the multi-point FMEA allows the FMEA, FMEDA, and FTA to link together and this is especially important to mechatronic and electronic designs.

Author information

Mary Rowzee is an Omnex consultant with extensive experience and achievements in Quality Systems development, implementation, and auditing to ISO 9000 series and IATF 16949 standards; Six Sigma Black Belt Problem Solving and Advance Quality Tools including Design and Process FMEA, Design and Process Verification, and Test Planning, Complex Statistical Analyses and Reliability Prediction, Modelling and Risk Reduction. Mary is a writing member of AIAG-VDA FMEA 1st edition and the Core Tools Guidelines: SPC 2nd edition, MSA 4th edition, EFMEA 1st edition, PPAP 4th edition, and APQP 2nd edition.

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