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Introduction to FMEA

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What is Risk in FMEA? Why Prevention Important?
Introduction to FMEA | Purpose & Key Benefits
History of FMEA – NASA to AIAG to AIAG-VDA
Types of FMEA – DFMEA, PFMEA, and FMEA-MSR
FMEA in APQP & IATF 16949 Context

Foundations of FMEA

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Function Requirement Failure in FMEA
Severity in FMEA (AIAG-VDA) | Explained with Examples
Occurrence in FMEA (AIAG-VDA) | Explained with Examples
Detection in FMEA (AIAG-VDA) | Explained with Examples
RPN vs Action Priority (AP) – Why RPN is Outdated
FMEA Linkages – ISO 9001, IATF 16949, APQP, PPAP.
Why AIAG-VDA 7-Step Approach?

Step-1: Planning & Preparation in FMEA

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Step 1 – Planning & Preparation in FMEA (AIAG-VDA Standard)
The Five Ts in FMEA – Intent, Timing, Team, Task, Tools
Defining Scope, Boundaries & Assumptions in FMEA
Cross-Functional Team Formation in FMEA

Step 2: Structure Analysis in FMEA

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Step 2 – Structure Analysis in FMEA
System, Subsystem, and Component Breakdown in FMEA
Process Flow – Structure Tree & Block Diagram in FMEA
Motor Stator Winding – Structure Analysis in FMEA Example

Step 3: Function Analysis in FMEA

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Step 3 – Function Analysis in FMEA
Defining Functions & Requirements in FMEA
How to Write Measurable Requirements in FMEA

Step 4: Failure Analysis in FMEA

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Step 4 – Failure Analysis in FMEA (Failure Modes, Effects, Causes)
Function Net in FMEA | Chain of Functions
Failure at Mode Level – Failure Modes
Effects of Failure in FMEA
Causes of Failure in FMEA (Design vs Process)
Cascading Failures – Failure Cause Mode Effect Relationship in FMEA

Step 5: Risk Analysis in FMEA

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Current Detection Controls in FMEA
Current Prevention Controls in FMEA (AIAG-VDA Standard)
Risk Evaluation in FMEA
Action Priority (AP) vs RPN in FMEA
Action Priority in FMEA (AIAG-VDA Standard)
Step 5 – Risk Analysis in FMEA
Severity in FMEA (AIAG-VDA) | Explained with Examples
Occurrence in FMEA (AIAG-VDA) | Explained with Examples
Detection in FMEA (AIAG-VDA) | Explained with Examples

Step 6: Optimization in FMEA

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Tracking & Closing Actions in FMEA
Step 6 – Optimization in FMEA

Step 7: Results Documentation in FMEA

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Customer Communication & Lessons Learned in FMEA
FMEA Report (Summary Table)
Step 7 – Results Documentation in FMEA

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