n Step 7: Results Documentation of the AIAG-VDA 7-Step FMEA approach, the final deliverable is often an FMEA Report.
👉 The Summary Table in the FMEA Report provides a concise overview of:
- What risks were identified.
- What actions were taken.
- What the results were after re-evaluation.
This summary is especially useful for management reviews, customer submissions, and audits because it highlights the most critical information without going through the entire FMEA sheet.
What is an FMEA Report? #
- A formal document summarizing the outcome of an FMEA project.
- Communicates to stakeholders that risks have been systematically identified, analyzed, and mitigated.
- Includes a Summary Table, which condenses the detailed analysis into an easy-to-read format.
📌 Customers and auditors often request the FMEA Report Summary Table as evidence of risk management.
Purpose of the FMEA Summary Table #
- Provide a high-level overview of FMEA results.
- Highlight critical risks and how they were addressed.
- Demonstrate compliance with AIAG-VDA and IATF 16949 requirements.
- Capture status of actions (open, completed, verified).
- Support decision-making for management and customer reviews.
Structure of an FMEA Report Summary Table #
A typical Summary Table contains the following columns:
| Column | Description |
|---|---|
| Item/Process Step | System, subsystem, component, or process being analyzed |
| Function | Intended function or requirement |
| Failure Mode | How the function could fail |
| Failure Effect | Impact of the failure (local, next-level, customer) |
| Severity (S) | Severity rating (1–10) |
| Cause of Failure | Why the failure mode could occur |
| Occurrence (O) | Occurrence rating (1–10) |
| Current Controls | Prevention or detection controls in place |
| Detection (D) | Detection rating (1–10) |
| AP (Before) | Initial Action Priority (High/Medium/Low) |
| Recommended Action | Suggested action to reduce risk |
| Action Owner / Due Date | Responsibility and timeline |
| AP (After) | Re-evaluated Action Priority after implementation |
| Status | Open, In Progress, Completed, Verified |
| Lessons Learned | Key insights for future projects |
Example – FMEA Summary Table (PFMEA for Bolting Process) #
| Item | Function | Failure Mode | Effect | S | Cause | O | Current Controls | D | AP (Before) | Action | AP (After) | Status |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Suspension bolt | Secure at 100 ± 5 Nm | Under-torque | Suspension loosens → safety risk | 9 | Torque wrench calibration drift | 6 | Manual torque audit | 7 | High | Introduce auto torque monitoring system | Medium | Completed |
| Suspension bolt | Secure at 100 ± 5 Nm | Over-torque | Thread damage → assembly rework | 6 | Operator applies excess force | 4 | Visual torque check | 6 | Medium | Introduce digital torque tool with shutoff | Low | Verified |
📌 This format clearly shows before vs after ratings, making it easy to see the effectiveness of actions.
Best Practices for FMEA Report & Summary Table #
- Keep it concise → Focus on high-priority risks (AP = High or Medium).
- Show improvement → Always include “before” and “after” ratings.
- Highlight lessons learned → Helps future projects avoid repeating issues.
- Standardize format → Use a common template across all projects.
- Link to control plans → Ensure actions flow into quality documentation.
- Keep it audit-ready → Evidence of risk evaluation and action closure.
Common Mistakes to Avoid #
- Submitting entire FMEA sheets instead of a summary → overwhelms reviewers.
- Failing to update “after ratings” after optimization.
- Not documenting open actions in the report.
- Using inconsistent formats → confuses management or customers.
- Treating the summary as paperwork, not a communication tool.
Why the FMEA Report Summary Matters #
- Provides clear communication of risk status.
- Helps management allocate resources effectively.
- Strengthens customer trust with transparent reporting.
- Ensures continuous improvement and knowledge sharing.
Key Takeaways #
- The FMEA Report Summary Table condenses FMEA into a clear, high-level document.
- Focuses on risks, actions, and results.
- Essential for management reviews, customer submissions, and audits.
- Must always show before vs after AP ratings to prove risk reduction.
Next Resource #
👉 Learn more about Lessons Learned in FMEA – Capturing Knowledge for Future Projects
