The Excel-based AIAG-VDA FMEA Template is a powerful yet accessible tool for quality engineers aiming to implement the 7-step FMEA methodology without the need for costly FMEA software. Whether you’re working on a Design FMEA (DFMEA) or Process FMEA (PFMEA), this Excel template helps structure your analysis, track risks, and document your preventive and detection actions—all in alignment with the AIAG-VDA FMEA Handbook.
In this article, we’ll walk you through each section of a typical Excel-based FMEA template, explaining how it aligns with the AIAG-VDA methodology and how you can use it effectively in your organization.
1. What is an Excel-Based AIAG-VDA FMEA Template? #
An Excel-based FMEA template is a structured spreadsheet that mirrors the AIAG-VDA 7-step FMEA approach, allowing teams to:
- Perform failure mode and effect analysis (DFMEA / PFMEA)
- Assign risk ratings (S, O, D)
- Apply Action Priority (AP)
- Document recommended actions
- Track action status and results
It’s particularly useful for small and mid-sized companies or engineers looking for a free and customizable alternative to licensed FMEA tools like APIS IQ-RM, PLATO SCIO, or Knowlence TDC.
2. Benefits of Using Excel for FMEA #
✅ Free & accessible
✅ Customizable for your processes
✅ Easy to share across teams
✅ Supports visual management (filters, colors)
✅ Can be linked with Control Plan, DFMEA → PFMEA transfer
3. Structure of the Template – Aligned to 7-Step Method #
The Excel template mirrors the AIAG-VDA 7-Step approach, which includes:
- Planning & Preparation
- Structure Analysis
- Function Analysis
- Failure Analysis
- Risk Analysis
- Optimization (Actions)
- Results Documentation
Each step is organized into separate sections or columns in the sheet for easy flow and traceability.
4. Walkthrough of Each Section #
Let’s walk through the standard column-wise structure of the Excel template:
🔹 General Information
- Project Name, FMEA Number, Revision, Date
- Team Members, Prepared By
🔹 Step 1: Planning & Preparation
- Scope
- Assumptions
- Customer Requirements
🔹 Step 2: Structure Analysis
- System/Subsystem
- Component or Process Step
- Next Higher and Next Lower Level
🔹 Step 3: Function Analysis
- Function
- Function Requirements / Targets
🔹 Step 4: Failure Analysis
- Failure Mode
- Effects of Failure
- Severity (S)
- Cause of Failure
- Occurrence (O)
🔹 Step 5: Risk Analysis
- Current Prevention Control
- Current Detection Control
- Detection (D)
- Action Priority (AP)
🔹 Step 6: Optimization
- Recommended Actions
- Responsible Person
- Target Date
- Status
- Action Taken
- New S, O, D (Post-action)
- New AP
🔹 Step 7: Results Documentation
- Lessons Learned
- Approval Signatures
- Date of Closure
5. How to Use the Template – Step-by-Step #
Here’s how you can use the Excel template for DFMEA or PFMEA:
✅ Step 1: Define Scope & System
Enter the product/process name, revision, scope, and assumptions.
✅ Step 2: Map the Structure
Break down your system or process step-by-step using hierarchy.
✅ Step 3: List Functions
Identify functions and their performance requirements.
✅ Step 4: Analyze Failures
List potential failure modes, effects, and causes for each function.
✅ Step 5: Rate Risks
Assign Severity, Occurrence, Detection → derive Action Priority using lookup table (provided).
✅ Step 6: Take Actions
Plan & implement preventive/detection actions. Update revised ratings and status.
✅ Step 7: Document Results
Summarize lessons learned, approvals, and close the FMEA.
6. Download Free Excel FMEA Template #
You can download a free, editable Excel-based FMEA template that follows AIAG-VDA guidelines from our website:
👉 Download FMEA Excel Template
This template includes:
- DFMEA & PFMEA sheets
- Built-in AP lookup logic
- Filterable columns
- Print-ready format
7. Tips for Effective Use #
✔ Use dropdowns for rating consistency (S, O, D values)
✔ Color code rows for Open / In Progress / Closed actions
✔ Protect formulas and use conditional formatting
✔ Link your DFMEA → PFMEA for better traceability
✔ Use filters to review high AP items first
8. Limitations of Excel-Based FMEA #
While Excel templates are great for starters, they may fall short when:
- Managing large, complex systems
- Handling multiple product variants
- Collaborating across global teams
- Linking to Control Plans or Test Plans dynamically
- Integrating with PPAP documentation or QMS systems
For advanced use, consider transitioning to tools like APIS IQ-RM, Plato SCIO, or Knowlence TDC.
9. Conclusion #
The Excel-based AIAG-VDA FMEA Template is a practical, cost-effective tool for performing both DFMEA and PFMEA in compliance with the 7-step method. It brings structure, traceability, and standardization to your risk analysis efforts—all within a familiar spreadsheet environment.
Whether you’re a quality engineer, process owner, or supplier, this template offers a solid starting point before moving to full-fledged FMEA software solutions.
10. Frequently Asked Questions (FAQs) #
❓ Is this Excel FMEA template compliant with AIAG-VDA Handbook?
Yes, it follows the 7-step structure, uses Severity/Occurrence/Detection ratings, and includes Action Priority tables.
❓ Can I use this template for both DFMEA and PFMEA?
Yes. The template includes separate sheets and columns tailored for design and process FMEA.
❓ How do I calculate Action Priority (AP) in Excel?
We’ve added a built-in lookup formula that assigns AP based on S, O, D combinations using AIAG-VDA standard tables.
❓ Can this template be linked to a Control Plan?
Yes. You can create a hyperlink or reference key column (e.g., process step ID) to maintain alignment with your Control Plan.
