Before starting into detailed steps of an AIAG-VDA FMEA, it’s important to first understand the Five Ts – Intent, Timing, Team, Task, and Tools. These 5 elements work as the planning steps of any FMEA activity.
When you apply 5Ts correctly, then they align the entire team around the objective, scope, responsibilities, timing, and software, to make sure a smooth and value-added analysis process.
In this article, we’ll break down each of the Five Ts in the scope of the AIAG-VDA 7-step FMEA approach, with practical examples from the automotive manufacturing environment.
1. Intent – Why Are You Doing This FMEA? #
The Intent defines the purpose of the FMEA. This includes understanding of what type of FMEA is being developed (e.g., DFMEA, PFMEA, FMEA-MSR), and what is the reason behind it? such as a new product launch, design change, process update, or customer requirement.
There are key Questions to Clarify Intent:
- Is this a new design, modified design, or an existing design being used in a new application?
- Is this a new process or a change in an existing process?
- Are there any specific OEM/customer requirements driving this FMEA?
Example:
A Tier-1 supplier is designing a new motor controller ECU for an electric vehicle. The intent of the DFMEA is to analyze design risks early, prevent potential electrical and thermal failures, and meet customer-specific requirements from Volkswagen.
Some other examples in type of FMEA perspective:
- DFMEA InTent: Ensure motor design meets temperature, EMC, and durability requirements. Identify and prevent design failures early.
- PFMEA InTent: Prevent welding process defects before production launch.
- FMEA-MSR InTent: Evaluate braking system monitoring during customer use.
A well-defined InTent gives best direction to FMEA and it’s not just a “form-filling” activity.
2. Timing – When Should the FMEA Be Performed? #
Timing tells us when the FMEA is initiated and updated during the product or process lifecycle. The AIAG-VDA standard focuses on that FMEA should be a preventive tool, not a reactive tool. It should be started early in the development process, before part is built or processes are finalized.
Key Timing Triggers:
- Start of concept phase (DFMEA)
- During process planning (PFMEA)
- When a design or process change occurs
- Before customer submission (PPAP)
- After field returns or warranty claims (as updates)
Example:
For a new welding process line, the PFMEA was started during the process design phase. It allows sufficient time to identify and analyze risks like weld spatter, improper electrode wear, and low nugget strength before SOP (Start of Production).
- DFMEA: During APQP Phase 2 (Product Design & Development).
- PFMEA: During APQP Phase 3 (Process Design & Development).
- Updates: After engineering changes, field feedback, or audit findings.
Rule: FMEA should always be a living document, not a one-time activity.
Read more: Why FMEA timing is more important.
3. Team – Who Should Be Involved? #
FMEA is always a cross-functional team activity. The Team must have members from all relevant departments and specialists, to make sure that design and process risks are properly identified, evaluated, and considered.
Recommended Team Members:
DFMEA: FMEA Moderator, Design engineer, systems engineer, quality engineer, functional safety expert, validation/testing, process/industrial engineer
PFMEA: FMEA Moderator, Process/industrial engineer, Design engineer, manufacturing engineer, quality engineer, maintenance, operator or supervisor
Example:
While preparing the PFMEA for a seat track assembly, the team included a process engineer, operator from the assembly line, a supplier quality engineer, and a customer quality representative to add lessons from field returns.
4. Task – What Needs to Be Done? #
The Task provides guidelines to the specific FMEA activities, responsibilities, and deliverables. It includes a clear definition of the scope, boundaries, and assumptions of the FMEA study. Properly defined tasks keep the FMEA project focused and aligned with timing and customer requirements.
Task Planning Covers:
- Define system, subsystem, or component being analyzed. (BOM)
- Determine interfaces and technical boundaries. (P-Diagram, Interface matrix)
- Define assumptions and exclusions (what’s in-scope vs out-of-scope) (Boundary Diagram)
- Align FMEA with related documents (Control Plan, DVP&R, boundary diagram, etc.)
Example:
The team defined the Task for the DFMEA of an airbag module by specifying the scope to include the inflator, housing, and deployment sensor, while excluding the ECU and wiring harness (analyzed separately). The boundary diagram was created in advance to support function and failure analysis.
5. Tools – Which Tools Will Be Used? #
The Tools are nothing but how do conduct the FMEA study. In which software you do this study. The software and support systems used to conduct the FMEA.
AIAG-VDA FMEA requires documentation of the 7-step approach and effective handling of complex product/process structures. Using the right software makes FMEA compliance, traceability, and version control.
Common FMEA Tools:
- Excel-based templates (for small-scale or legacy projects)
- APIS IQ-RM – Advanced structure & action tracking
- Plato SCIO – Visual risk analysis with clear structure trees
- Knowlence TDC – Excellent for project and team management
- OEM-specific tools (e.g., Honda’s PQCT, GM’s GQTS)
Example:
A PFMEA for a gluing process in battery pack assembly was managed using APIS IQ, which provided real-time linkage with the Control Plan and allowed seamless updates after design changes in the CAD structure.
Best Practices for Applying the Five Ts #
- Use a FMEA Planning Checklist that considers each of the Five Ts before the kickoff meeting.
- Document lessons learned from past FMEAs to improve Intent and Task definitions.
- Set internal deadlines and milestones for Timing.
- Maintain a core team and subject matter experts for Family or platform FMEAs.
Read more: What is Family FMEA?
Summary: The Five Ts helping in FMEA Success #
Understanding and applying the Five Ts-Intent, Timing, Team, Task, Tools put the groundwork for your FMEA. These elements will ensure that the activity is purposeful, timely, collaborative, focused, and technically supported.
Without proper planning, this best risk analysis tools fail to provide you with actionable risk outcomes.
So, before jumping into structure analysis or brainstorming failure modes, pause and make sure your Five Ts are clearly defined and documented. It’s the first step toward a preventive quality culture in automotive manufacturing.
Yes. The Five Ts are universal and form the planning phase for both DFMEA and PFMEA in the AIAG-VDA methodology.
Use a standardized FMEA Planning Form or Project Charter format, which includes sections for each of the Five Ts. You can refer/download above attached 5T checksheet.
Technically yes, but it often leads to poor scoping, delays, and misalignment. Starting with the Five Ts is a best practice.
