Move from FMEA 3rd to 4th Editions Beginning November 1, 2008, the Chrysler, Ford, and GM, Failure

Mode Effects Analysis Reference Manual, 4th edition, available from AIAG, will supersede the 3rd edition. The 4th edition of the FMEA Reference Manual expands on the efforts of the 3rd edition by treating the entire FMEA process rather than just the forms in order to minimize the improper uses and implementation of the FMEA, such as: Column shifting: placing information in the wrong columns thus hindering the analysis and product / process improvement efforts Deflation of the RPN to obtain an arbitrarily set threshold Sole reliance on the RPN in the evaluation of risk priorities and improvement actions Focusing only on the completion of the FMEA form and not on the knowledge contained therein Lack of understanding of the role of the FMEA process throughout the APQP phases including continual improvement during production; i.e., looking at the FMEA as a static document necessary only for PPAP approval. th The 4 edition also contains discussion which will allow organizations with a mature FMEA process to go beyond the basic implementation and not be subject to nonconformances by auditors who only have a cursory knowledge of the FMEA process or attempt to audit to the manual as a standard.

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Overview:
Focus 3rd edition How to fill out a standard DFMEA and PFMEA form Not addressed Not addressed Not addressed Oriented towards a single form 4th edition How to develop and document a FMEA with emphasis on DFMEA and PFMEA Addressed Addressed Addressed Minimal elements to be documented identified (carry over from 3rd edition form). Alternate forms allowed and examples given. DFMEA and PFMEA element discussions made consistent with uniqueness identified. Consistent with new SAE J-1739 being developed Default risk analysis metric is RPN but allows alternate analysis acceptable by the customer. Exclusive use of RPN to determine action priority is not recommended The use of an RPN threshold is not considered an acceptable practice for determining the need for recommended actions. Addressed Multiple examples and graphics used to communicate concepts.

APQP relationships FMEA development process Prerequisite activities Documentation

Documentation

DFMEA and PFMEA element discussions not consistent Consistent with current SAE J1739 Only risk analysis metric discussed

S, O, D rankings RPN

RPN

No discussion on thresholds

Linkages Examples

Not addressed Single example for DFMEA and PFMEA

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Table of Contents:
3rd edition General Information Overview What Is an FMEA Manual Format 4th edition Chapter I GENERAL FMEA GUIDELINES Introduction o FMEA Process o Purpose of Manual o Scope of Manual Organization and Management for FMEA Product and Process Development Process Due Diligence On-going Maintenance Chapter II GENERAL FMEA Strategy, Planning, Execution Introduction Basic Structure Methodology Management Responsibility Chapter III DFMEA Design Failure Mode and Effects Analysis Introduction o Customer Defined o Team Effort o Manufacturing, Assembly and Serviceability Considerations Development of a Design FMEA Prerequisites o Block (Boundary) Diagrams o Parameter (P) diagrams o Other Tools and Information Sources o Evaluation of the functional requirements and Interface diagrams o Interface diagrams o Team Design FMEA Form Information o Header o Body Follow-Up Actions Maintaining DFMEAs Leveraging DFMEAs Linkages o Design Validation Plan & Report (DVP&R) Comments Expanded to include prerequisites and considerations for the entire FMEA process.

FMEA Implementation Follow Up

Expanded to include the entire FMEA process. This section provides the general foundations for FMEAs including those other than Design and Process. It also provides a pedagogical tool to assist in education and training for the development of FMEAs. New: Highlighted areas The form information is presented as minimal elements necessary for an FMEA rather than requiring a specific form be used as in the 3rd edition. The description of the minimum information required expands on that in the 3rd edition but was made consistent with that in the Process FMEA section

Design FMEA Introduction o Customer Defined o Team Effort Development of a Design FMEA o Header elements o Body elements Follow-Up Actions

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o o

PFMEA DFMEA Process Mapped to APQP or Product Development Process New: Highlighted areas

Process FMEA Introduction o Customer Defined o Team Effort Development of a Process FMEA o Header elements o Body elements Follow-Up Actions

APPENDICES Design FMEA Quality Objectives Process FMEA Quality Objectives Design FMEA Block Diagram Example Standard Forms for Design FMEA Design FMEA Example System FMEA Standard Forms for Process FMEA Process FMEA Example Suggested PFMEA Occurrence Evaluation Criteria With Ppk Values Glossary

Chapter IV PFMEA Process Failure Mode and Effects Analysis Introduction o Customer Defined o Team Effort o Design Considerations Development of a Process FMEA Prerequisites Process FMEA Form Information o Header o Body Follow-Up Actions Linkages o To other FMEA related Documents o To DFMEA o To Control Plan APPENDICES Appendix A: Sample Forms o DFMEA Forms o PFMEA Forms Appendix B System Level FMEAs Appendix C: o Alternative Risk Analysis Appendix D: Alternative Techniques o Fault Tree Analysis, (FTA) o FMECA o DRBFM Glossary References Index

The form information is presented as minimal elements necessary for an FMEA rather than requiring a specific form be used as in the 3rd edition. The description of the minimum information required expands on that in the 3rd edition but was made consistent with that in the Design FMEA section

New: Highlighted areas Removed: cyan highlighted area Sample forms include forms consistent with 3rd edition as well as examples of forms with additional information elements. Occurrence values are related to special causes not common cause variation; PPAP requirement focuses on common cause variation

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