The final step of the AIAG-VDA 7-Step FMEA methodology is Results Documentation.
👉 This step answers two key questions:
- “How do we report the results of the FMEA to stakeholders?”
- “How do we capture and reuse lessons learned for future projects?”
Without proper documentation, all the efforts in FMEA — from planning to optimization — risk being lost, repeated, or misunderstood.
Objectives of Results Documentation #
- Communicate FMEA outcomes clearly to stakeholders (management, customers, auditors).
- Provide evidence that risks were evaluated and mitigated.
- Document lessons learned for future design and process improvements.
- Ensure traceability and compliance with standards (IATF 16949, AIAG-VDA, customer-specific requirements).
What is Results Documentation in FMEA? #
- A summary report of the FMEA project showing:
- Scope, team, and methodology.
- Key risks identified.
- Actions taken and their effectiveness.
- Updated risk ratings (S, O, D, AP).
- Open issues or actions still pending.
- Includes a knowledge capture element (lessons learned database).
📌 Documentation is not just for customers — it also helps internal teams avoid repeating mistakes.
Key Elements of FMEA Results Documentation #
1. Reporting
- Summarize the FMEA project details:
- FMEA type (DFMEA, PFMEA, FMEA-MSR).
- Scope and boundaries.
- Cross-functional team members.
- Highlight:
- High-priority risks (before actions).
- Actions implemented.
- Re-evaluated ratings (after actions).
- Provide clear status of all recommended actions.
Example Report Snapshot – PFMEA Welding Process:
- Failure Mode: Weak weld.
- Initial AP: High.
- Action: Introduced automatic electrode monitoring.
- Re-evaluated AP: Medium.
- Status: Closed.
2. Lessons Learned
- Capture knowledge gained during the FMEA process.
- Feed into a centralized database or knowledge system.
- Examples of lessons learned:
- Design weakness discovered and corrected.
- Supplier quality issues identified early.
- Process controls that were highly effective.
- Lessons learned should be accessible for future projects.
📌 Example: If a bolting PFMEA identified that digital torque tools reduced risks significantly, this becomes a lesson for all future PFMEAs involving bolting.
3. Documentation Format
- Standardized templates recommended by AIAG-VDA.
- Tools: Excel, APIS IQ-RM, Plato SCIO, Knowlence TDC.
- Must meet customer-specific reporting requirements (CSRs).
- Should be linked with APQP deliverables like Control Plan and PPAP.
Case Study – DFMEA for Electric Motor #
- Initial Results:
- Failure Mode: Winding overheating.
- Severity = 9, Occurrence = 5, Detection = 6 → AP = High.
- Optimization Actions:
- Changed insulation material.
- Added thermal cutoff sensor.
- Final Results:
- Occurrence = 2, Detection = 3 → AP = Medium.
- Lessons Learned:
- Standardize high-temp insulation for all new motor designs.
- Documentation:
- Report shared with management and stored in lessons learned database.
Best Practices for Results Documentation #
- Use standardized templates to ensure consistency.
- Keep reports concise and clear — focus on risks, actions, and results.
- Highlight safety and compliance-related risks in reports.
- Integrate lessons learned into future FMEAs.
- Review documentation periodically during audits and management reviews.
- Make lessons learned accessible across the organization, not just to one team.
Common Mistakes to Avoid #
- Treating FMEA results as paperwork instead of communication.
- Failing to capture lessons learned → mistakes repeat in future projects.
- Not linking FMEA results to control plans, PPAP, and APQP deliverables.
- Closing reports without verifying that actions were effective.
- Keeping documentation siloed instead of shared across departments.
Why Results Documentation Matters #
- Provides evidence of risk management to customers and auditors.
- Helps teams reuse knowledge instead of repeating work.
- Demonstrates a culture of continuous improvement.
- Strengthens compliance with AIAG-VDA and IATF 16949 standards.
Key Takeaways #
- Results Documentation = reporting + lessons learned.
- Reports show what risks were found, what actions were taken, and what results were achieved.
- Lessons learned ensure knowledge is reused across future projects.
- Step 7 makes FMEA a sustainable risk management system instead of a one-time exercise.
Next Resource #
👉 Explore FMEA Documentation Best Practices for Manufacturing Companies
