Introduction to AIAG & VDA FMEA.pdf

Aauga and vda fmea

1. Failure Mode &
Effect Analysis
(FMEA)
AIAG & VDA -1
st
Edition
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VDA-FMEA
Excel Template

2. History Of FMEA
US Military
1949’s
NASA
1960’s
Ford Auto
Industry
1970’s
AIAG
1982’s
AIAG&VDA
2019’s
✓FMEA’s have been used as a risk identification and reduction tool for decades.
✓Developed by the US Military in the late 1940’s.
✓Used for almost 70 Year’s with relatively small evolutionary enhancements.
✓In 2019,Substantial changes were introduced as AIAG & VDA “harmonized” their
difference for conducting FMEA’s
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3. Failure Mode and Effects Analysis FMEA is a structured too to,
✓Identify failure modes for a process
✓Estimate its effect and the risk associated with it
✓Identify and Prioritize probable causes of failure
✓Prioritize the failure modes based on the Action Priority
✓Evaluate and develop control plan to contain the risk
What is FMEA?
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4. ✓Yes,FMEA is a quality tool. This tool helps to minimize or eliminate
failures in product design/manufacturing process and improve
quality.
Is FMEA a Quality Tool?
Why FMEA?
✓To avoid product recall
✓To avoid customer dissatisfaction
✓To avoid loss of market share
✓To avoid loss of reputation
✓To avoid repair and rework cost
✓To avoid legal action
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5. ✓New 7 Step Approach (PS 2F RO R)
✓Revised Severity, Occurrence and detection rating
✓RPN replaced by AP
✓New FMEA sheet in color with linkage
✓PFD is integral part
✓Use of 5T & 4M Approach
✓Recommended Action replaced by Prevention & Detection Action
✓Added Status of Action
✓Added special characteristics to replace classification
✓Added FMEA-MSR
Key Changes in AIAG & VDA FMEA
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6. ✓On time delivery of the quality product to customers
✓Higher accuracy in designing & manufacturing of products
✓Better control pf verification and validation of design
✓Less rework in the design phase
✓No/Very low risk of product failure
✓Less/No rework and repair
✓Better customer satisfaction.
Benefits of FMEA
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7. APQP Phases Vs FMEA
APQP
Phases
Planand Define
Program
Product Design&
Development
Verification
Process Design &
Development
Verification
Product &
Production
Validation
Feedback Assessment
& Corrective Action
DFMEA
Start FMEA planning
inconcept phase
before product
development begins
Information flow
from DFMEA to
PFMEA
The DFMEA and
PFMEA should be
executed during the
same time period to
allow optimization of
both the product and
process designs
Start DFMEAwhen
the design concept
is well understood
Complete DFMEA
analysis prior to
release of design
specifications for
quotation
Complete DFMEA
actions prior to
startof production
tooling
Start againwith
DFMEA and PFMEA
planning if there are
changes to an
existing design or
process
PFMEA
Start PFMEAwhen
the production
concept is well
understood
Complete PFMEA
analysis prior to final
process decisions
Complete PFMEA
actions prior to
PPAP
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8. 7 Step Approach
•In this step where plans are
developed that reduce risk
and increase customer
satisfaction by improving
the design or process.
•In this step the level of risk
for each failure mode is
evaluated in terms of
Severity, Occurrence and
Detection (S-O-D).
•Items are then assigned an
Action Priority Level of High,
Medium or Low.
•Marks the beginning of the
next phase of the FMEA,
Failure Analysis and Risk
Mitigation.
•The purpose of the Failure
Analysis Step is to identify
failure modes, failure effects
and failures causes to
establish the basis for risk
assessment.
•It is the final step where the
results of the FMEA study
are fully documented in a
report.
•It covers the scope definition, project team
make-up and project planning aspects of
the study.
•A clear definition of the scope, set by the
management team, minimizes the
probability of “scope creep."
•Project Planning is done following “Five
T’s” and should be covered in the FMEA
kickoff meeting.
•The information from this step is the basis
for Step 2.
•Used to identify and breakdown the
system (design or process) into the
system, subsystems and component
elements so that a comprehensive risk
assessment can be conducted.
•This information is the basis for the next
step
•Analyzes each System Element
identified in Step 2 in terms of its
intended function(s) and
corresponding requirements.
•The Function Analysis leads to a
comprehensive and relevant Failure
Analysis in Step 4.
1.Planning and Preparation 2.Structure Analysis 3.Function Analysis
4.Failure
Analysis
5.Risk Analysis6.Optimization
7.Result
Documentation
Section 1 : System Analysis
Section 2 : Failure Analysis & Risk MitigationSection 3 : Risk Analysis
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9. ✓inTent: What is and isn't included in the scope of this project and why is the FMEA being
undertaken?
✓Timing: When will the FMEA be done? (includes when in the product/process
development cycle to conduct the study with deadlines for completing the FMEA).
✓Team: Who will be on the core team and extended team and what are the members'
roles and responsibilities?
✓Tasks: What work needs to be done by the team?
✓Tools: What tools will the team use or will the team need to complete the project.
5T Approach
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10. The concept of a “Failure Chain” helps to visualize failures as part of three links of a chain comprised of
the Failure Effect (FE), Failure Mode (FM) and Failure Cause (FC). In turn, this clarity will help assign
meaningful S-O-D Ratings.
Failure Chain Model
3.Next Lower-Level Element
Failure Cause:Why is the failure mode
happening?
1.Next Higher-Level Element
Failure Effect: What happens in the event
of a failure mode?
2.Focus Element
Failure Mode:Failure to perform an
intended function or met requirements
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11. Design-FMEAs and Process-FMEAs use the (familiar) S-O-D approach to evaluate risk.
✓Severity (S) is an estimate of how serious the impact of the failure effect would be assuming that a
specific failure mode occurred. To determine the Severity, consider the impact the effect would
have on a customer, a customer's operation, your operation, your customer’s operation, and end-
user or the people working with the product or process.
✓Occurrence (O) reflects the prediction of each Failure Cause Occurring based on the type of control
(behavioral, technical or best practice methodology). For Prevention Controls with multiple
Occurrence Ratings, use the rating that best reflects the robustness of the control.
✓Detection (D) is used to depict the relative effectiveness of the system to either prevent a potential
failure mode or failure cause or to detect a failure mode or cause has occurred
S-O-D Rating Table
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12. The new AIAG-VDA FMEA process places greater emphasis on PREVENTION vs
DETECTION.
For a Design-FMEA, Detection Controls are the basis of the robustness of the
design. Prevention Controls describe how a potential cause that may result in a
Failure Mode will be mitigated while Detection Controls are intended to detect (not
mitigate) the potential existence of a Failure Cause or Failure Mode.
For a Process-FMEA, emphasis is placed on Prevention Controls (that eliminate
the Failure Cause or reduce its rate of occurrence) as well as Detection Controls
(that detect a Failure Cause or Failure Mode).
Prevention Vs Detection
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13. AIAG & VDA FMEA SCORING
Severity (S)
Occurrence (O)
Detection (D)
Safe Dangerous
Less Possibility/Never Happens Likely to happen
Defect can be detected and not pass No detection
Failure Impact Severity
Rating (FE)
Potential cause of
Failure Rating Value (FC)
Detection or process
control method Rating
(FC or FM)
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14. Action Priority (AP) Table
Action Priority Table is a risk matrix that can represent combinations of S-O, S-D and O-D, each resulting in
either a High, Medium or Low Action Priority.
AP High (H)
Actionto improve prevention and/or
detection controls (or justification on why
current controls are adequate) MUST be
taken.
AP Medium (M)
Actionto improve prevention and/or
detection controls (or justification on why
current controls are adequate) SHOULD
be taken.
AP Low (L)
Actionto improve prevention and/or
detection controls COULD be taken.
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15. ✓The payoff of an effective and efficient FMEA is a reduction of COQ
✓FMEAs and Cost of Quality go hand-in-hand, While the immediate benefit of the
FMEA is mitigation of risk, it should translate into a reduction in the Cost of
Quality (COQ).
✓FMEA comes under the Prevention & Appraisal Cost categories, An efficient
FMEA will see Failure costs will go down substantially more than the
corresponding increase in Prevention and Appraisal Costs.
FMEA and COQ
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16. FMEA MSR’s
✓Intended to help maintain a safe state or state of regulatory
compliance during customer operation.
✓Introduced to ensure functional safety goals (as required by
ISO 26262) have been fully considered and are met.
✓A significant focus of the analysis is to determine if the system or the
end user will detect a failure if one does occur.
✓Used as a supplement to a DFMEA
✓It uses the same seven-step process used for DFMEAs and PFMEAs.
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17. Follow me on LinkedIn @balajilrfor Quality & EV Related Contents Balaji L R
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