MoveFMEA3rdto4thwhitepaper

8/6/2019 MoveFMEA3rdto4thwhitepaper

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G.F. Gruska 2007 Page 1

Move from FMEA 3rd

to 4th

Editions

Beginning November 1, 2008, the Chrysler, Ford, and GM, Failure Mode Effects

AnalysisReference 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 hinderingthe 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 theAPQP phases including continual improvement during production; i.e.,

looking at the FMEA as a static document necessary only for PPAP

approval.

The 4th

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:

3rd

edition 4th

edition

Focus How to fill out a standard DFMEA

and PFMEA form

How to develop and document a

FMEA with emphasis on DFMEA

and PFMEA

APQP relationships Not addressed Addressed

FMEA development process Not addressed Addressed

Prerequisite activities Not addressed Addressed

Documentation Oriented towards a single form Minimal elements to be

documented identified (carry over

from 3rd edition form). Alternate

forms allowed and examples given.

Documentation DFMEA and PFMEA element

discussions not consistent

DFMEA and PFMEA element

discussions made consistent with

uniqueness identified.

S, O, D rankings Consistent with current SAE J-

1739

Consistent with new SAE J-1739

being developed

RPN Only risk analysis metric discussed Default risk analysis metric is RPNbut allows alternate analysis

acceptable by the customer.

Exclusive use of RPN to determine

action priority is not recommended

RPN No discussion on thresholds The use of an RPN threshold is not

considered an acceptable practice

for determining the need for

recommended actions.

Linkages Not addressed Addressed

Examples Single example for DFMEA and

PFMEA

Multiple examples and graphics

used to communicate concepts.


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Table of Contents:

3rd

edition 4th

edition Comments

General Information

Overview What Is an FMEA Manual Format

Chapter I

GENERAL FMEA GUIDELINES

Introductiono FMEA Processo Purpose of Manualo

Scope of Manual Organization and Management for

FMEA

Product and Process DevelopmentProcess

Due Diligence On-going Maintenance

Expanded to include prerequisites and

considerations for the entire FMEA

process.

FMEA Implementation Follow Up Chapter IIGENERAL FMEA Strategy, Planning,

Execution

Introduction Basic Structure Methodology Management Responsibility

Expanded to include the entire FMEA

process.

This section provides the general

foundations for FMEAs including those

other than Design and Process. It alsoprovides a pedagogical tool to assist in

education and training for the development

of FMEAs.

Design FMEA

Introductiono Customer Definedo Team Effort

Development of a DesignFMEA

o Header elementso Body elements

Follow-Up Actions

Chapter III

DFMEA Design Failure Mode and

Effects Analysis

Introductiono Customer Definedo Team Efforto Manufacturing, Assembly

and Serviceability

ConsiderationsDevelopment of a Design FMEA

Prerequisiteso Block (Boundary) Diagramso Parameter (P) diagramso Other Tools and Information

Sources

o Evaluation of the functionalrequirements and Interface

diagrams

o Interface diagramso Team

Design FMEA Form Informationo Headero Body

Follow-Up Actions Maintaining DFMEAs Leveraging DFMEAs Linkages

o Design Validation Plan &Report (DVP&R)

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 the3rd edition but was made consistent with

that in the Process FMEA section


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o PFMEAo DFMEA Process Mapped to

APQP or Product

Development Process

Process FMEA

Introductiono Customer Definedo Team Effort

Development of a ProcessFMEA

o Header elementso Body elements

Follow-Up Actions

Chapter IV

PFMEA Process Failure Mode and

Effects Analysis

Introductiono Customer Definedo Team Efforto Design Considerations

Development of a Process FMEA

Prerequisites Process FMEA Form Information

o Headero Body

Follow-Up Actions Linkages

o To other FMEA relatedDocuments

oTo DFMEA

o To Control Plan


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

APPENDICES

Design FMEA QualityObjectives

Process FMEA QualityObjectives

Design FMEA BlockDiagram Example

Standard Forms for DesignFMEA

Design FMEA Example System FMEA Standard Forms for Process

FMEA

Process FMEA Example Suggested PFMEA

Occurrence Evaluation

Criteria With Ppk Values Glossary

APPENDICES

Appendix A: Sample Forms

o DFMEA Formso PFMEA Forms

Appendix B System Level FMEAs

Appendix C:

o Alternative Risk AnalysisAppendix D:

Alternative Techniques

o Fault Tree Analysis, (FTA)o

FMECAo DRBFM

Glossary

References

Index


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; PPAPrequirement focuses on common cause

variation