Failure mode and effects analysis (FMEA) is one of the most important tools for successful quality management in companies. While traditional methods often rely on rigid forms, the AIAG&VDA standard has established a more comprehensive approach: instead of just documenting errors, this method focuses on networked thinking and working as well as proactive error prevention.
With its seven-stage process model, the AIAG&VDA standard has established itself as best practice across all industries. Modern FMEA software plays a key role here, enabling companies to implement the method simply and efficiently.
This blog article explains the core steps of the AIAG & VDA standard, why structure networks are a real game changer for companies and how FMEA software makes the entire process easier.
FMEA according to AIAG & VDA - The standard for quality assurance
The FMEA manual was published in 2019 by the Automotive Industry Action Group (AIAG) and the German Association of the Automotive Industry (VDA) - a milestone for quality standards in the automotive industry. It sets guidelines and standards that car manufacturers and their suppliers must adhere to. So, anyone who supplies components to European or North American car manufacturers or OEMs (Original Equipment Manufacturers) cannot avoid the AIAG&VDA-FMEA. The aim of this standard is to continuously improve quality in the automotive industry, learn from mistakes and avoid them in the long term.
The AIAG&VDA FMEA is based on a clearly structured, seven-stage process model that has now even become established across all industries:
In contrast to the classic FMEA, where faults are often simply listed on a form, the AIAG&VDA method focuses on a deeper, networked analysis of risks and dependencies. Steps 2, 3 and 4, which systematically break down the respective structure from coarse to fine, are particularly important:
- Step 2: Analyze system structure
This step consists of analyzing the system structure in detail and creating a structural network. What components are there? How are they connected? The structural net provides a clear overview and forms the basis for the next steps.
- Step 3: Networking functions
The functions of the individual elements are then identified and mapped in a function net. This makes it clear what dependencies exist and how individual functions influence each other - the basis for subsequent failure analysis.
- Step 4: Uncover failure chains
This step is about deriving possible errors, understanding their interrelationships and linking them in a failure net. This systematic approach ensures a detailed and networked view of the entire object of analysis and ensures that no important connections are overlooked.
These steps result in the three central nets of AIAG & VDA-FMEA:
- Structural net (yellow): Shows the structure of the system and how the components are interconnected.
- Functional net (green): Links the functions of the individual system elements and shows which functions they perform.
- Failure network (red): Derives failures from the functions, clarifies dependencies and shows what effects they have on the entire system.
This integrated approach means that defects are not only documented but also understood holistically in their context - a crucial prerequisite for sustainable quality improvements throughout the entire manufacturing process.
Why thinking in nets is superior
In contrast to traditional forms, the network structure makes dependencies and interrelationships recognizable at an instant. The result is a complete picture of all systems and processes. Companies benefit from this three-stage analysis in several ways:
- More insight into complex systems - structures become clearer and easier to understand.
- Fewer blind spots - critical correlations are not overlooked.
- Better error prevention - problems are identified at an early stage, documented and systematically avoided.
The switch to net structures therefore not only ensures a deeper analysis, but also greater security and efficiency in quality management.
The role of modern FMEA software
Conventional FMEA in table form quickly reaches its limits and does not meet the high requirements of modern quality management processes. If you want to analyze network structures properly and really penetrate them, you need specialized FMEA software. A fact that car manufacturers (OEMs) as well as module and system suppliers (Tier 1) have been aware of for a long time. This is why they specifically require their suppliers to use appropriate software solutions.
A suitable FMEA software offers these specific advantages:
- Automatic creation of structure/function and defect nets: no tedious manual sorting of defect lists
- Seamless integration into the FMEA form: simple linking of net structures with the risk analysis
- Greater efficiency and precision: avoidance of duplicate work steps plus a better overview - with the right software, FMEA is not only more accurate, but also significantly more time-saving
- Flexibility for individual requirements: with the right software, FMEA can be implemented much more efficiently and strategically - a real game changer for companies
Conclusion
The classic form FMEA is increasingly becoming a thing of the past. Companies that consistently apply the AIAG&VDA standard and rely on modern FMEA software secure clear advantages: they benefit from improved error prevention through systematic networks, more efficient processes through automation and fulfill important OEM requirements. The future of quality management lies in networked thinking, working and acting. FMEA software is the decisive tool for successfully shaping this change and ensuring the highest quality in the long term.
