Report Purpose
The FMEA Coverage Report answers critical safety compliance questions:
- What is the total count of failure modes analyzed?
- Which design requirements and safety-classified characteristics lack corresponding failure mode analysis?
- What is the post-mitigation action priority distribution across all FMEAs?
- Which system elements have incomplete FMEA documentation?
- What FMEA coverage gaps exist relative to ISO 26262 or AIAG-VDA requirements?
This report is essential for:
- ISO 26262 functional safety compliance audits (Part 4 requirements traceability)
- AIAG-VDA FMEA Handbook compliance verification
- Design review gate decisions (FMEA completeness criteria)
- Traceability evidence for safety-critical characteristics
Report Structure
The FMEA Coverage Report is implemented as a Velocity dashboard page that queries the Polarion work item database and renders multiple coverage analysis sections.
| Report Section | Content | Metrics |
|---|
| Executive Summary | Overall FMEA coverage statistics | Coverage %, gap count |
| DFMEA Coverage | Design FMEA analysis completeness | Items analyzed vs. total |
| PFMEA Coverage | Process FMEA analysis completeness | Items analyzed vs. total |
| Coverage by System Element | Breakdown by subsystem/component | Per-element coverage |
| Coverage by Process Step | Breakdown by manufacturing step | Per-step coverage |
| Gap Analysis | Uncovered items requiring attention | Priority ranking |
Key Metrics and KPIs
Design FMEA (DFMEA) Metrics
| Metric | Query | Meaning |
|---|
| Total Failure Modes | type:failureMode | Count of all design failure modes across system/subsystem/component hierarchy |
| DFMEA by System Element | type:failureMode AND systemElement:* | Failure modes grouped by parent system element to identify incomplete analysis |
| Action Priority Distribution | type:failureMode AND preAPValue:* | Breakdown of H/M/L action priority ratings to assess risk concentration |
| Post-Mitigation Coverage | type:failureMode AND (postAPValue:* OR postmitigationAP:*) | Percentage of failure modes with post-mitigation actions completed |
| High Priority Actions | type:failureMode AND preAPValue:"H" | Count of High priority failure modes requiring immediate risk control |
Process FMEA (PFMEA) Metrics
| Metric | Query | Meaning |
|---|
| Total Process Failure Modes | type:processFailureMode | Count of manufacturing/process-level failure modes |
| PFMEA by Process Step | type:processFailureMode AND parentProcess:* | Process failure modes grouped by parent process step |
| RPN Distribution | type:processFailureMode AND (riskPriority:* OR rpnValue:*) | Risk Priority Number distribution to identify high-risk process steps |
| Control Plan Item Linkage | type:controlPlanItem AND linkedWorkItems:mitigates=PF* | Percentage of control plan items linked to process failure modes |
| High RPN Actions | type:processFailureMode AND rpnValue:>=300 | Process failures with RPN ≥ 300 requiring special process controls (SPC) |
Design requirements classified as Safety-Critical (SC) or Safety-Significant (SS) characteristics must have corresponding failure mode analysis. The report highlights any SC/CC design requirements without linked failure modes as compliance violations under ISO 26262 and IATF 16949.
Coverage Gap Analysis
Design FMEA Gaps
The report identifies the following gap categories:
| Gap Type | Description | Query Pattern | ISO 26262 Impact |
|---|
| Uncovered Design Req | Design requirement with no linked failure modes | type:desReq AND safetyClassification:SC AND NOT linkedWorkItems:assesses=FM* | Part 5 §7.4.2 (Design FMEA mandatory for safety-related functions) |
| Uncovered Characteristic | Characteristic with safetyClassification but no failure mode analysis | type:characteristic AND (sccc:SC OR sccc:CC) AND NOT linkedWorkItems:assesses=FM* | Part 4 §5.7 (SC characteristics require FMEA) |
| Uncovered Function | Function allocated to safety-critical system element without FMEA | type:function AND linkedWorkItems:allocatedTo=SE* AND NOT linkedWorkItems:assesses=FM* | Part 5 requirements traceability |
| Incomplete Post-Mitigation | Failure mode without post-mitigation rating after risk control | type:failureMode AND NOT (postmitigationAP:* OR postAPValue:*) | Part 4 §8.3.2 (Post-mitigation verification required) |
| Missing Risk Control | High/Medium priority failure mode without linked risk control | type:failureMode AND (preAPValue:"H" OR preAPValue:"M") AND NOT linkedWorkItems:mitigates=RC* | Part 4 §6.3.2 (Risk control mandatory for ASIL B+) |
Process FMEA Gaps
| Gap Type | Description | Query Pattern | IATF/APQP Impact |
|---|
| Uncovered Process Step | Process step without corresponding failure mode analysis | type:processStep AND NOT linkedWorkItems:hasFailureModes=PF* | IATF 16949 Process FMEA requirement |
| Uncovered Process Characteristic | Process characteristic without control plan item | type:processStep AND linkedWorkItems:hasCharacteristics=PC* AND NOT linkedWorkItems:controlledBy=CP* | APQP Control Plan completeness |
| Missing Detection Method | Process failure mode without defined detection strategy | type:processFailureMode AND NOT detection:* | ISO 9001 SPC requirement |
| High RPN — No Action | Process failure mode with RPN ≥ 300 without assigned risk control | type:processFailureMode AND rpnValue:>=300 AND NOT linkedWorkItems:mitigates=RC* | PPAP quality requirement |
Click any coverage bar gap query link to drill down into the specific work items needing analysis. This generates a Lucene search result showing all uncovered items, which you can then process using bulk editing in the Risks space.
Configuration Properties
Dashboard Page Properties
| Property | Type | Default | Description |
|---|
space | String | "Risks" | Polarion space containing FMEA and coverage reports |
page_title | String | "FMEA Coverage Report" | Display title of the dashboard page |
report_date | Velocity Expression | $date | Auto-populated report generation timestamp |
project_prefix | String | "TA" | Project prefix used in Lucene queries (e.g., type:failureMode AND id:TA*) |
show_dfmea_section | Boolean | true | Enable/disable Design FMEA coverage section |
show_pfmea_section | Boolean | true | Enable/disable Process FMEA coverage section |
show_gap_analysis | Boolean | true | Enable/disable gap analysis tables and drill-down links |
KPI Card Configuration
| Property | Type | Example | Description |
|---|
kpi_label | String | "Total DFMEA Failure Modes" | Display label for KPI card |
kpi_query | Lucene Query | "type:failureMode" | Work item query for KPI computation |
kpi_color | CSS Color | "#1565c0" (blue) | Card background color (hex or CSS variable) |
kpi_icon | Icon Class | “ | Material Design icon for visual emphasis |
kpi_threshold_warning | Number | 80 | KPI value threshold for yellow warning state |
kpi_threshold_critical | Number | 100 | KPI value threshold for red critical state |
#set( $dfmea_count = $queryFactory.executeQuery("type:failureMode").size() )
#nxKpiCard("Total DFMEA Failure Modes" $dfmea_count "blue")
Coverage Bar Configuration
| Property | Type | Example | Description |
|---|
coverage_label | String | "Design Requirements → Failure Modes" | Coverage dimension label |
coverage_numerator_query | Lucene Query | "type:desReq AND linkedWorkItems:assesses=FM*" | Work items WITH coverage (covered set) |
coverage_denominator_query | Lucene Query | "type:desReq AND safetyClassification:SC" | Total work items requiring coverage (total set) |
coverage_gap_query | Lucene Query | "type:desReq AND safetyClassification:SC AND NOT linkedWorkItems:assesses=FM*" | Gap drill-down query (what’s missing) |
coverage_threshold_green | Number | 100 | Coverage % for green (complete) state |
coverage_threshold_yellow | Number | 80 | Coverage % for yellow (incomplete) state |
#nxLinkCoverage( "type:desReq AND safetyClassification:SC" "failureMode" "assesses" "outgoing" )
#set( $gap_query = "type:desReq AND safetyClassification:SC AND NOT linkedWorkItems:assesses=FM*" )
#nxCoverageBar( $covered_count $total_count "Design Requirements" $gap_query )
Report Sections in Detail
Design FMEA Coverage By System Element
This section breaks down DFMEA coverage by system hierarchy level:
| Level | Entity | Coverage Metric |
|---|
| System | System Element | % of elements with DFMEA analysis |
| Subsystem | Subsystem Function | % of functions with failure modes |
| Component | Component Characteristic | % of characteristics with controls |
- Count: Total failure modes for that element
- Action Priority Distribution: H/M/L breakdown
- Post-Mitigation Coverage %: Percentage with post-AP assigned
- Risk Controls Linked: Count of mitigating risk controls
- Gap Count: Design requirements or characteristics without FMEA
Process FMEA Coverage By Process Step
This section tracks manufacturing process FMEA completeness:
| Level | Entity | Coverage Metric |
|---|
| Process | Process Step | % of steps with PFMEA analysis |
| Characteristic | Process Characteristic | % of characteristics with controls |
| Control | Control Plan Item | % of items with reaction plans |
Action Priority and RPN Distribution
The report displays histograms of action priority ratings to identify risk concentration:
Design FMEA Action Priority Distribution:
| Priority | Count | % | Interpretation |
|---|
| H (High) | 52 | 20% | Immediate action required; high safety impact |
| M (Medium) | 156 | 60% | Planned action during design phase |
| L (Low) | 52 | 20% | Accept risk or mitigate via testing/controls |
| Pending | 0 | 0% | Unassigned action priority (gap) |
| RPN Range | Count | Risk Level | Control Type |
|---|
| RPN ≥ 300 | 3 | Critical | Mandatory SPC |
| 150–300 | 8 | High | Enhanced SPC or Inspection |
| 50–150 | 5 | Medium | Routine Process Control |
| < 50 | 0 | Low | Accept or Audit |
Linking to Related Pages
The FMEA Coverage Report connects to other TestAuto2 documentation:
Report Limitations and Known Issues
On projects with >500 failure modes, the FMEA Coverage Report may take 10–15 seconds to render due to Lucene query complexity. Consider filtering by system element or process step for faster drill-down analysis.
The coverage percentage for post-mitigation ratings reflects the snapshot at report generation time. If risk controls are still in draft status, the post-mitigation field may not be auto-populated until the risk control work item transitions to “Complete” status.
Process FMEA uses RPN (Severity × Occurrence × Detection) while Design FMEA uses Action Priority (H/M/L) per AIAG-VDA 2019. These metrics are not directly comparable and should be evaluated independently.
See Also
