In 2019, AIAG (Automotive Industry Action Group) and VDA (Verband der Automobilindustrie – German Automotive Association) released a joint FMEA Handbook. This new AIAG-VDA 7-Step Approach replaced the old AIAG 4th Edition (2008) method.
Why was this change necessary? Because suppliers working with global OEMs (US, German, Japanese, etc.) faced confusion, duplication, and inconsistencies when preparing FMEAs. The new handbook provides a single, structured, and globally accepted FMEA methodology.
Why the 7-Step FMEA Approach Was Introduced #
Global Alignment
- Before 2019, US OEMs (GM, Ford, Chrysler) followed AIAG guidelines, while German OEMs (VW, BMW, Daimler) followed VDA guidelines.
- This created duplication: suppliers had to maintain two different FMEA formats for the same part.
- The AIAG-VDA Handbook merged both approaches into one standardized method.
Structured Methodology
- The 7-Step approach provides a clear, logical process flow.
- Each step builds on the previous, ensuring no shortcuts or missing elements.
Focus on Risk Prevention, Not Just Documentation
- Old FMEAs often became “check-the-box” documents.
- The new approach emphasizes practical risk prevention and continuous improvement.
Improved Risk Evaluation
- Action Priority (AP) replaced the old RPN, solving many of its weaknesses.
- Ensures safety and high-severity risks are never ignored.
The 7 Steps of AIAG-VDA FMEA #
- Planning & Preparation
- Structure Analysis
- Function Analysis
- Failure Analysis
- Risk Analysis (S, O, D, AP)
- Optimization (Actions & Re-evaluation)
- Results Documentation (Reporting & Lessons Learned)
These steps ensure consistency and completeness across all FMEAs (Design, Process, MSR).
Key Differences: AIAG-VDA 7-Step vs AIAG 4th Edition #
| Aspect | AIAG 4th Edition (2008) | AIAG-VDA Handbook (2019) |
|---|---|---|
| Methodology | Based on RPN (S × O × D) | Based on 7 structured steps |
| Risk Evaluation | RPN used as priority measure | Action Priority (AP) table used |
| Standardization | US suppliers (AIAG only) | Global alignment (AIAG + VDA) |
| Approach | Linear worksheet-based | Process-driven, step-by-step |
| Documentation | Focus on filling forms | Emphasis on risk prevention & lessons learned |
| Types of FMEA | DFMEA, PFMEA | DFMEA, PFMEA, + FMEA-MSR |
| Linkages | Weak link to Control Plan | Strong linkage to Control Plan & PPAP |
| Flexibility | More open interpretation | Standardized tables, definitions, and templates |
Example: Brake System Failure Mode #
Old Method (AIAG 4th Edition):
Severity = 10, Occurrence = 2, Detection = 3 → RPN = 60 → Considered “not high priority.”
New Method (AIAG-VDA 7-Step):
Severity = 10 automatically drives High Action Priority (H). Ensures safety-critical risks are considered.
This shows how the new approach prevents critical risks.
Benefits of the AIAG-VDA 7-Step Approach #
- Consistency: All OEMs and suppliers now follow a common method.
- Clarity: Structured 7 steps avoid confusion and incomplete analysis.
- Safety-first: Severity-driven Action Priority ensures safety-critical risks are never ignored.
- Efficiency: Reduces duplicate FMEAs for global suppliers.
- Improvement-focused: Encourages tracking of actions and continuous improvement.
Key Takeaways #
- The AIAG-VDA 7-Step Approach was introduced in 2019 to unify AIAG and VDA methods.
- It replaced RPN with Action Priority (AP) for more accurate risk evaluation.
- It focuses on risk prevention, lessons learned, and control plan integration.
- All suppliers working with OEMs must now use this standardized method.
