Step 4: Failure Analysis in FMEA Archives

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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RPN vs Action Priority (AP) – Why RPN is Outdated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

DFMEA in Practice

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DFMEA in Practice – Step‑by‑Step
DFMEA Audit Readiness
DFMEA Optimization Step
DFMEA Risk Analysis
DFMEA Failure Analysis
DFMEA Function Analysis
DFMEA Structure Analysis
Product Snapshot – DFMEA in Practice (Step-by-Step)

PFMEA in Practice

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PFMEA Audit Readiness
PFMEA Results Documentation
PFMEA Optimization step
PFMEA Risk Analysis
PFMEA Failure Analysis
PFMEA Function Analysis
PFMEA Structure Analysis
PFMEA Planning and Preparation
PFMEA Process Snapshot
PFMEA in Practice – Step‑by‑Step

FMEA Linkages

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📘 Case Study: How DFMEA Links to PFMEA and Control Plan — A Practical Guide
How FMEA Links to PPAP Deliverables
Prevention and Detection Controls in PFMEA to Control Plan | How to Link Them
How FMEA Drives Control Plans in Manufacturing Quality
FMEA and Control Plan Linkage

FMEA Tools & Templates

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Excel vs Professional FMEA Software: Explain
FMEA in APIS IQ, PLATO SCIO, and Knowlence TDC: Overview of Top FMEA Software Tools
Excel-Based AIAG-VDA FMEA Template (Walkthrough)

FMEA Best Practices

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FMEA Moderation: Common Mistakes & Best Practices
Common Mistakes & Best Practices in FMEA Creation

FMEA Advanced Applications

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Future of FMEA – AI, Automation & Digital Technology
FMEA Use Cases in EVs, Welding, Electronics & Embedded Systems
Internal & Customer FMEA Audit Preparation
FMEA Moderation Techniques for Cross-Functional Teams
Advanced Failure Cause Modeling in FMEA
Family FMEA – Save Time Across Product Lines
FMEA in APQP Phases and Project Milestones
Using FMEA in Functional Safety (ISO 26262)
What is System FMEA? Scope, Structure & Interface Analysis
Which FMEA Software Should You Choose?
Software for FMEA
How FMEA Links with Control Plan, PPAP & Special Characteristics

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FMEA Knowledge base
Step 4: Failure Analysis in FMEA

Step 4: Failure Analysis in FMEA

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

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