In Step 6: Optimization of the AIAG-VDA 7-Step FMEA approach, teams define recommended actions to reduce risk.
👉 But an action is only valuable if it is:
- Tracked until completion, and
- Closed with evidence that it reduced the risk.
Tracking & Closing Actions ensures that FMEA is not just a document, but a living risk management tool.
What is Action Tracking in FMEA? #
- Definition: Monitoring the progress of recommended actions from assignment to completion.
- Purpose: Ensure no high-priority risks are left unresolved.
- Method: Use action logs, FMEA software, or project management tools.
📌 Each action must include:
- Responsible person (owner).
- Target completion date.
- Status (Open, In Progress, Completed, Verified).
What is Action Closing in FMEA? #
- Definition: Formal verification that the recommended action has been implemented and is effective.
- Purpose: Update FMEA with new Occurrence and Detection ratings after the action.
- Outcome: Risk reduced to acceptable levels (AP downgraded from High → Medium or Low).
Key Elements of Tracking & Closing Actions #
1. Action Assignment
- Each action must be assigned to a specific owner.
- Example: PFMEA welding → Action: Introduce electrode life monitoring. Owner: Process Engineer.
2. Target Dates
- Define clear deadlines based on risk priority (AP).
- High (H) = immediate action. Medium (M) = planned within project timeline. Low (L) = documented justification.
3. Action Status Tracking
- Typical status categories:
- Open
- In Progress
- Completed (pending verification)
- Closed (verified effective)
4. Verification of Effectiveness
- Actions must be validated using:
- Design verification tests (DFMEA).
- Process capability, SPC data, audits (PFMEA).
- Lessons learned feedback.
5. Updating FMEA Ratings
- After action closure:
- Severity (S): Usually unchanged.
- Occurrence (O): Updated if prevention actions succeed.
- Detection (D): Updated if detection actions improve.
- AP (Action Priority): Recalculated to confirm acceptability.
Example – Tracking & Closing Actions in PFMEA (Bolting) #
- Failure Mode: Under-torque bolt.
- Cause: Torque wrench calibration drift.
- Action: Introduce digital torque tool with automatic shut-off.
- Owner: Manufacturing Engineer.
- Target Date: June 15.
- Status: Completed → Verified by torque audit.
📌 Re-Evaluation:
- Old O=6, D=7 → AP = High.
- New O=2, D=3 → AP = Medium.
- Action Closed → Documented in FMEA with updated ratings.
Case Study – DFMEA Electric Motor Insulation #
- Failure Mode: Winding overheats.
- Cause: Insulation breakdown at 150°C.
- Action: Upgrade insulation to 180°C, add thermal cutoff sensor.
- Owner: Design Engineer.
- Status: Completed → Verified by design validation test.
- Re-Evaluation:
- Old O=5, D=6 → AP=High.
- New O=2, D=3 → AP=Medium.
- FMEA updated, action officially closed.
Best Practices for Tracking & Closing Actions #
- Use structured logs or software to track actions (APIS IQ, Excel, project management tools).
- Assign owners and due dates for accountability.
- Prioritize High AP actions → must be completed before production launch.
- Verify with data (SPC, audits, validation tests) before closing.
- Update FMEA document after re-evaluation of ratings.
- Communicate progress in regular FMEA review meetings.
- Feed lessons learned into future projects.
Common Mistakes to Avoid #
- Leaving actions open without follow-up.
- Closing actions without proof of effectiveness.
- Lowering ratings without validation data.
- Assigning actions to “teams” instead of specific individuals.
- Not updating FMEA after action closure.
Why Tracking & Closing Actions is Critical #
- Ensures High Priority risks are eliminated before launch.
- Provides evidence for audits and OEM requirements.
- Builds customer trust → demonstrates proactive risk management.
- Transforms FMEA from paperwork into a continuous improvement tool.
Key Takeaways #
- Tracking actions = monitoring progress. Closing actions = verifying and documenting effectiveness.
- Actions must have owners, deadlines, and status.
- FMEA ratings (O, D, AP) must be updated after closure.
- Closing actions ensures FMEA delivers real-world risk reduction.
Next Resource #
👉 Learn more about Step 7: Results Documentation (Reporting & Lessons Learned)
