Skip to content
logo_color
  • Free FMEA Course
  • Services
Contact Us
Contact Us
logo_color

Introduction to FMEA

5
  • 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

7
  • 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  • RPN vs Action Priority (AP) – Why RPN is Outdated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

4
  • 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

4
  • 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

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

Step 4: Failure Analysis in FMEA

6
  • 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

9
  • 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

2
  • Tracking & Closing Actions in FMEA
  • Step 6 – Optimization in FMEA

Step 7: Results Documentation in FMEA

3
  • Customer Communication & Lessons Learned in FMEA
  • FMEA Report (Summary Table)
  • Step 7 – Results Documentation in FMEA

1

3
  • Doc 1
  • 1.1
    • Doc 1.1
  • 1.3
    • Doc 1.3

2

1
  • 2.1
    • Doc 2.1

4

1
  • Doc 4
View Categories
  • Home
  • FMEA Knowledge base
  • Step 5: Risk Analysis in FMEA
  • Current Detection Controls in FMEA

Current Detection Controls in FMEA

FMEA Expert
Updated on September 6, 2025

3 min read

In Failure Modes and Effects Analysis (FMEA), the AIAG-VDA handbook defines two types of controls:

  1. Prevention Controls → Prevent the cause of failure from occurring.
  2. Detection Controls → Identify the failure cause or mode if it occurs, before it reaches the customer.

👉 Current Detection Controls focus on identifying failures, not preventing them. They determine the Detection (D) rating in FMEA.


What are Current Detection Controls? #

  • Definition: Current Detection Controls are the methods, inspections, or tests already in place to discover causes or failure modes before the product reaches the customer.
  • Purpose: Reduce the probability that a failure will escape undetected.
  • Focus: Verification, testing, inspections, monitoring, audits.

📌 Key Rule: Detection does not prevent a failure — it only improves the chance of catching it.


Types of Current Detection Controls #

1. Design Detection Controls (DFMEA)

  • Design verification tests.
  • Durability & reliability tests.
  • Simulation (CAE, FEA, software-in-the-loop).
  • Prototype evaluations.

Example – DFMEA Electric Motor:

  • Failure Mode: Winding short circuit.
  • Detection Control: High-voltage insulation test on prototype.

2. Process Detection Controls (PFMEA)

  • In-process inspections (visual checks, dimensional checks).
  • Statistical Process Control (SPC) with alarms.
  • 100% automated checks (sensors, gauges).
  • End-of-line testing (functional, leak test, torque test).
  • Audits and sampling plans.

Example – PFMEA Bolting Process:

  • Failure Mode: Under-torque bolt.
  • Detection Control: Digital torque monitoring system with alarms.

Examples of Current Detection Controls #

FMEA TypeFailure ModeDetection ControlDetection Rating Impact
DFMEA – ECU SoftwareLogic errorAutomated diagnostic self-testRating 2 (almost certain detection)
PFMEA – WeldingWeld nugget missingVisual inspection by operatorRating 7–8 (weak detection)
PFMEA – PaintingThin coatingRandom thickness samplingRating 6 (moderate detection)
DFMEA – Brake SystemSensor signal errorHardware-in-loop testingRating 3 (very reliable detection)

📌 Strong detection controls (error-proofing, 100% automated tests) = low Detection rating (1–3).
📌 Weak detection controls (manual checks, random audits) = high Detection rating (7–10).


How Detection Controls Influence FMEA #

  • Detection ratings are not about preventing failures — they only measure how well current methods catch failures before release.
  • Example:
    • Visual check of bolts → Detection = 7 (weak).
    • Automatic torque verification → Detection = 2 (strong).

👉 Better detection controls → lower Detection rating → improved Action Priority (AP).


Best Practices for Current Detection Controls #

  1. Be realistic: Manual inspection is weak, rarely better than D=6–7.
  2. Prefer automation: Sensors, alarms, error-proofing are far more reliable (D=1–3).
  3. Document detection methods clearly: Who checks, how, and at what frequency.
  4. Validate detection effectiveness: Use MSA (Measurement System Analysis) and calibration.
  5. Link to control plans: In PFMEA, ensure detection methods align with process control plans.
  6. Update controls: After adding new technology, re-evaluate Detection ratings.

Common Mistakes in Detection Controls #

  • Treating detection as prevention (they are not the same).
  • Overestimating manual inspections → assuming operators will always catch defects.
  • Copying detection ratings from past FMEAs without validation.
  • Not documenting evidence of effectiveness (no calibration, no audits).

Case Study – PFMEA for Painting Process #

  • Function: Apply protective coating.
  • Failure Mode: Coating thickness too thin.
  • Current Detection Control: Random sampling with micrometer → Detection rating = 6.
  • Improvement: Automated coating thickness measurement (100% check) → New rating = 2.

👉 Result: Risk reduced significantly because failures can be detected before delivery.


Why Detection Controls are Important in FMEA #

  • They determine how much uncontrolled risk reaches the customer.
  • They drive Detection rating (D) in FMEA → critical for Action Priority.
  • They highlight where process improvements (automation, sensors, poka-yoke) are needed.
  • They ensure compliance with IATF 16949 and OEM requirements for robust quality control.

Key Takeaways #

  • Current Detection Controls = methods to discover failures before they escape.
  • Strong detection = low Detection rating (1–3). Weak detection = high rating (7–10).
  • Always document detection controls in detail.
  • Detection reduces risk but does not replace prevention — prevention is always stronger.
  • Updating detection methods improves FMEA credibility and reduces risk priority.

Next Resource #

👉 Learn more about FMEA Optimization – Step 6 in AIAG-VDA Approach

Updated on September 6, 2025

Are this content helpful..

  • Happy
  • Normal
  • Sad

Share This Article :

  • Facebook
  • X
  • LinkedIn
  • Pinterest
Current Prevention Controls in FMEA (AIAG-VDA Standard)
Table of Contents
  • What are Current Detection Controls?
  • Types of Current Detection Controls
  • Examples of Current Detection Controls
  • How Detection Controls Influence FMEA
  • Best Practices for Current Detection Controls
  • Common Mistakes in Detection Controls
  • Case Study – PFMEA for Painting Process
  • Why Detection Controls are Important in FMEA
  • Key Takeaways
  • Next Resource
  • Free FMEA Course
  • Services
Contact Us
Contact Us
logo_color

One touch solution for FMEA documentation training or creation and support.

Learn

  • Knowledge base
  • Training
  • Newsletter

Company

  • About Us
  • Contact
  • Services
  • Products

Connect

© 2025 Quality Assist

Powered by Quality Assist