AIAG VDA FMEA Alignment – A Paradigm Shift in the Making

Background

Prior to the alignment, automotive suppliers providing products to North American and German OEM customers are required to perform FMEA differently as the method prescribed by the AIAG FMEA manuals are different from that of VDA FMEA manuals. This creates confusion and require additional resources.

Key Changes of AIAG VDA FMEA

A first draft has since been published for comments in November of 2017. Based on the first draft, some of the key changes are highlighted below.

1. The new FMEA adopted a six-step approach for both Design FMEA and process FMEA.
2. The six steps are:
   • Scope Definition
   • Structure analysis
   • Function Analysis
   • Failure Analysis
   • Risk Analysis
   • Optimization
3. The failure analysis is now more in-depth with a 3 dimensional perspective analysis incorporating a focus element, its higher level and lower elements. This is done with the objective to make the failure chain clearer, enhancing readability of the Cause-Faillure Mode-Effect relationship.
4. Noticeable distinction between Severity ranking for 9 and 10. Safety is now rank 10 regardless of with or without warning. 9 is strictly reserved for regulatory related non-compliance.
5. RPN is replaced by AP (Action Priority) with a High-medium-low built into several tables for S, O and D. The writing committee emphasize that AP is not a ‘risk priority’, instead it is a priority for action to reduce the risk of failure to function. Separate tables are to available to assess AP in design FMEA and process FMEA.
6. Improvement Action is replaced by an enlarged Optimization phase. The actions is now distinctive with dedicated columns to define prevention action and detection action taken as part of improvement action.

Lastly, if you are wondering by now, the length of the FMEA worksheet is now wider horizontally.

When will the new AIAG-VDA FMEA manual be published?

“The final release of the new FMEA manual was widely expected by December 2018 but the date was missed. There has been no official explanation for the delay. It is now widely expected to be within Q2 of 2019. Keep a look out for it!”

” Genius is one percent inspiration and ninety-nine percent perspiration.” – Thomas Edison

Note: We are compiling a FAQs for the impact of new FMEA, come back to this blog soon to check it out!

Written by Leon Ng

Leon Ng is our Managing Partner with years of hands-on consulting experience in FMEA. He can be contacted at [email protected]