🧠 Introduction
Whether it’s a customer audit, an IATF 16949 surveillance audit, or your internal quality review, your FMEA will be under the spotlight.
Auditors look for more than just filled-out forms. They want to see:
- Structured methodology
- Cross-functional involvement
- Linkage with Control Plan and PPAP
- Documented decisions and traceability
This post provides a complete FMEA audit checklist—covering both internal reviews and customer expectations—to help you prepare confidently.
🔍 1. Why FMEA Audits Are Critical
| Audit Type | Purpose |
|---|---|
| Internal Audit | Ensure FMEA is aligned with project and quality goals |
| Customer Audit | Verify that risks are identified, controlled, and traceable |
| IATF/ISO Audit | Validate compliance with AIAG-VDA and standard requirements |
💡 A well-audited FMEA reflects maturity, risk awareness, and customer focus.
📋 2. Internal FMEA Audit Checklist
Use this to self-assess before external audits or reviews:
| ✅ Checkpoint | 🎯 Description |
|---|---|
| Scope Defined | Scope, boundaries, assumptions clearly documented |
| 5T Planning Done | Involvement of all required stakeholders |
| Structure Complete | Product/process hierarchy is correct |
| Function Analysis | All functions mapped with clear requirements |
| Failure Modes | Each function has logical failure modes |
| Causes | Causes are specific, actionable, and not vague |
| Effects | Effects are linked to customer/system impact |
| Severity Ratings | Consistent with organization’s criteria |
| Controls | Prevention and Detection controls are realistic and current |
| Action Priority Used | AP is used (not RPN) and actions are risk-driven |
| Action Tracking | Assigned to owners, with due dates and status updates |
| Revision History | Each update version is traceable with reason |
| Lessons Learned | Previous projects’ feedback is included or referenced |
✅ Downloadable PDF version at the end of this blog.
📦 3. Customer Audit Expectations
Customers often expect:
| 💬 Expectation | 📌 Evidence Auditors Look For |
|---|---|
| AIAG-VDA Compliance | 7-Step structure clearly followed |
| Cross-functional Team | Meeting invites, attendance records |
| Control Plan Linkage | One-to-one linkage with PFMEA controls |
| Special Characteristics | SCs consistently marked in DFMEA, PFMEA, Control Plan, Drawings |
| PPAP Readiness | Aligned FMEA, Control Plan, MSA, Dimensional Results |
| Revision Control | Signed-off versions and approval logs |
| Actions Closed | Status of high AP items with effectiveness check |
💡 Tip: Prepare a “FMEA Audit Folder” with your latest FMEA, Control Plan, AP log, and SC list ready to present.
🧰 4. Tools & Techniques for Audit Readiness
- APIS IQ RM / PLATO SCIO / TDC FMEA:
- Built-in version control
- Action tracking modules
- Audit-ready reports
- Excel Tips:
- Use change logs and timestamp macros
- Color-code actions and status
- Link SCs with drawing references
📌 5. Common FMEA Audit Findings (and How to Fix Them)
| ❌ Audit Finding | ✅ Fix |
|---|---|
| Generic or copy-paste failure modes | Use actual design/process inputs |
| No evidence of team involvement | Maintain attendance & review logs |
| Ratings inconsistent across FMEAs | Train team on unified rating tables |
| Missing linkage to Control Plan | Use a cross-reference matrix |
| Actions open for months | Set review cadence with reminders |
| Lessons not learned | Document feedback loops post-launch |
✅ Summary
| To pass your FMEA audit… |
|---|
| Follow the 7-step AIAG-VDA methodology |
| Maintain traceability with Control Plan, PPAP |
| Keep actions tracked and updated |
| Involve the full cross-functional team |
| Regularly review and improve FMEA quality |
Audits don’t need to be stressful—if your FMEA tells a clear story of risk discovery, action, and prevention, you’re already ahead.
📥 Download Free Resource:
📄 [Internal + Customer FMEA Audit Checklist (PDF)] (Insert download link)
🔁 Coming Up Next in the Series:
Post #11: FMEA Use Cases in EVs, Welding, Electronics & Embedded Systems
🔗 Internal Links to Add:
/control-plan//fmea-functional-safety-iso26262//ppap-documentation//fmea-moderation-techniques/← Previous post
