AIAG-VDA 7-Step FMEA Wizard

NirmIQ includes a fully compliant AIAG & VDA FMEA Handbook 7-step wizard for conducting structured, industry-standard Failure Mode and Effects Analysis.

Overview

The AIAG-VDA 7-step methodology is the modern standard for FMEA, replacing the traditional approach with a more structured, comprehensive process. This methodology was jointly developed by the Automotive Industry Action Group (AIAG) and the German Association of the Automotive Industry (VDA).

The 7 Steps

Step 1: Planning & Preparation (5T's)

The foundation of any successful FMEA starts with proper planning using the 5T's approach:

T	Meaning	Description
InTent	Purpose & Scope	What are you analyzing and why?
Timing	Schedule	Key milestones and deadlines
Team	Cross-functional	Who should be involved?
Task	Objectives	What are the deliverables?
Tool	Software/Standards	NirmIQ + AIAG-VDA Handbook

Key Outputs:

• Clear scope definition
• Team assignments
• Project timeline
• Success criteria

Step 2: Structure Analysis (P-Diagram)

Build a visual hierarchy of your system:

System (Top Level)
├── Subsystem
│   ├── Component
│   │   ├── Part
│   │   └── Characteristic
│   └── Component
└── Subsystem

Key Concepts:

• System: The complete product or process being analyzed
• Subsystem: Functional groups within the system
• Component: Individual parts or assemblies
• Functions: What each element should DO

Pro Tip: Link structure elements to requirements for complete traceability.

Step 3: Function Analysis

Define what each structure element should DO:

• Functions: Describe intended behavior
• Requirements: Link to formal requirements
• Interfaces: How elements interact

Example functions:

• "Monitor battery temperature"
• "Detect sensor failure"
• "Execute emergency stop"

Step 4: Failure Analysis (Failure Net)

Identify potential failures using the Failure Chain:

Effect (Impact) ← Failure Mode (What fails) ← Cause (Why it fails)

Failure Mode: How a function can fail

• Example: "Sensor fails to detect obstacle"

Effects: What happens when it fails

• Example: "Vehicle does not stop, potential collision"

Causes: Root cause of the failure

• Example: "Sensor contamination, electrical short"

Step 5: Risk Analysis

Evaluate each failure mode using the S-O-D rating system:

Rating	Severity (S)	Occurrence (O)	Detection (D)
10	Hazardous	Very High	Cannot Detect
7-9	Very High	Moderate-High	Remote
4-6	Moderate	Low-Moderate	Moderate
2-3	Minor	Remote	High
1	None	Nearly Impossible	Almost Certain

Action Priority (AP) is automatically calculated:

AP	Criteria	Action Required
High (H)	S ≥ 9, or S ≥ 7 with O ≥ 4 or D ≥ 4	Immediate action required
Medium (M)	S ≥ 4, or S = 3 with O ≥ 6 or D ≥ 6	Should take action
Low (L)	All other combinations	Could improve, monitor

Step 6: Optimization

Define and track mitigation actions:

Action Types:

• Preventive Actions: Reduce Occurrence (O)

  • Design changes
  • Process improvements
  • Added controls

• Detection Actions: Improve Detection (D)

  • Additional testing
  • Monitoring systems
  • Error-proofing

Action Tracking:

• Responsible person
• Target date
• Status (Pending, In Progress, Completed)
• Effectiveness rating
• RPN reduction tracking

Step 7: Results Documentation

Export and share your FMEA results:

Report Types:

• Full FMEA Report: Complete AIAG-VDA compliant form
• FMEA Worksheet: Standard worksheet for printing
• Action Status Report: Track optimization progress
• Executive Summary: High-level overview for management

Export Formats:

• Excel (.xlsx) - Best for data analysis
• PDF - Best for sharing
• Print - Direct to printer

How to Access the Wizard

1. Navigate to your project's FMEA tab
2. Toggle Advanced Mode at the top
3. Create or open an FMEA analysis
4. Click Open 7-Step Wizard button

The wizard guides you through each step sequentially, tracking completion status as you go.

Industry Templates

NirmIQ includes starter templates for various industries:

Industry	Template	Includes
Automotive	OBD-II Diagnostics	Ford DFMEA structure, DTCs, rating scales
Automotive	Battery Management	BMS structure tree, failure modes
Aerospace	Flight Control System	DO-178C compliance, safety analysis
Medical	Infusion Pump	IEC 62304 compliance, risk analysis
Space	Satellite Systems	Redundancy analysis, failure modes
Electronics	Consumer Electronics	Component failure library
Industrial	Manufacturing Equipment	Process FMEA template

Templates include:

• Pre-built structure trees
• Failure mode libraries by component
• Industry-standard rating scales
• DTC libraries (automotive)
• Compliance standard references

Compliance Standards

The 7-step wizard supports these industry standards:

• AIAG & VDA FMEA Handbook (2019) - Primary methodology
• ISO 26262 - Automotive functional safety (ASIL)
• DO-178C - Aerospace software (DAL)
• IEC 62304 - Medical device software
• IEC 61508 - Industrial functional safety (SIL)
• NASA-STD-8719.13 - Space systems safety

Best Practices

Team Composition

Include representatives from:

• Design Engineering
• Manufacturing/Process Engineering
• Quality Assurance
• Reliability Engineering
• Customer/Field Support

Timing

• Start FMEA during concept phase, not after problems occur
• Update throughout product lifecycle
• Review before major design changes

Common Mistakes to Avoid

1. Starting too late - FMEA is preventive, not reactive
2. Working alone - FMEA requires cross-functional input
3. Focusing only on RPN - Action Priority is more important
4. Not following up - Track and verify action effectiveness
5. Copy-paste from old FMEAs - Each analysis should be tailored

What's Next?

• Create Your First Advanced FMEA
• Build a Structure Tree
• Use Risk Analytics
• Understanding S-O-D Ratings