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Create FMEA Documents
Learn how to set up System, Design, and Process FMEA modules with proper risksheet integration.
Identify Failure Modes
Define potential failure modes, effects, and causes using structured risksheet templates.
Assess Risk Parameters
Evaluate Severity, Occurrence, and Detection ratings to drive risk prioritization.
Calculate Action Priority
Compute RPN (Risk Priority Number) and Action Priority (H/M/L) to focus mitigation efforts.
Link Risk Controls
Connect design and process controls to failure modes, track effectiveness, and manage post-mitigation ratings.
Generate Reports
Create comprehensive FMEA coverage reports, risk matrices, and traceability summaries for compliance.
FMEA Methodology Overview
The FMEA process in TestAuto2 follows the AIAG-VDA 7-step methodology, with workflow views that adapt as you progress through analysis stages:
Workflow Structure
| Guide | Purpose | Start With |
|---|---|---|
| Create System FMEA Document | Set up SFMEA module and initialize risksheet | New FMEA analysis |
| Create Design FMEA Document | Create component-level FMEA linked to SFMEA | Design decomposition |
| Create Process FMEA Document | Build manufacturing FMEA from process steps | Manufacturing planning |
| Define Failure Modes | Identify potential failures, effects, and causes | Brainstorming session |
| Assess Severity, Occurrence, Detection | Rate pre-mitigation risk parameters | Initial risk evaluation |
| Calculate Action Priority | Compute RPN and H/M/L priority classification | Risk ranking |
| Link to Risk Controls | Connect failure modes to design/process controls | Mitigation strategy |
| Track Post-Mitigation Ratings | Assess control effectiveness and residual risk | Control verification |
| Link to Upstream SFMEA | Establish bidirectional DFMEA ↔ SFMEA traceability | Design refinement |
| Use Progressive Workflow Views | Navigate risksheet views that adapt per analysis stage | Daily work |
| Generate FMEA Reports | Produce compliance reports and risk summaries | Evidence generation |
Key Concepts
- Failure Mode: A potential manner in which a system element could fail (e.g., “throttle actuator commands 100% opening when idle”).
- Severity (S): Rating (1-10) of potential harm if the failure occurs while operating.
- Occurrence (O): Rating (0-10) of probability the failure will occur during product life.
- Detection (D): Rating (0-10) of likelihood the control system will detect the failure before harm.
- Action Priority (AP): High (H), Medium (M), or Low (L) — derived from RPN and Severity, determines mitigation urgency.
- Risk Control: A design or process change that reduces Severity or Occurrence (e.g., “add redundant sensor”).
- Post-Mitigation Ratings: Updated S/O/D after control implementation, showing residual risk.
Common Tasks
- Create a new FMEA document
- Add failure modes to a risksheet
- Assign Severity/Occurrence/Detection ratings
- Calculate Action Priority from RPN
- Connect failure modes to risk controls
- Generate FMEA coverage and risk reports