Report Architecture Overview
TestAuto2 implements a dual-FMEA approach separating Design FMEA (DFMEA) analysis from Process FMEA (PFMEA) analysis, each with dedicated reporting dashboards, Risksheet configurations, and work item types.
FMEA reports serve as executive dashboards for safety engineers and program managers to visualize failure mode coverage, track mitigation status, and identify high-risk items requiring immediate action.
FMEA Report Types
Design FMEA (DFMEA) Reports
Design FMEA reports analyze failures at three decomposition levels: system, subsystem, and component. Each level focuses on functional failures and their detection.
| Report | Scope | Work Item Type | Key Metric | Typical Count |
|---|
| System DFMEA | System-level functions | failureMode | Action Priority (AP) | 36–50 modes |
| Subsystem DFMEA | Subsystem functions | failureMode | Action Priority (AP) | 28–42 modes |
| Component DFMEA | Component characteristics | failureMode | Action Priority (AP) | 7–24 modes |
Action Priority (AP) = Severity × Occurrence × Detection
AP Range: 1–1000 (lower values indicate lower risk)
AP Thresholds:
• H (High): AP ≥ 200
• M (Medium): AP 50–199
• L (Low): AP < 50
Process FMEA (PFMEA) Reports
Process FMEA reports analyze manufacturing process failures and their control. PFMEA uses Risk Priority Number (RPN) instead of AP.
| Report | Scope | Work Item Type | Key Metric | Typical Count |
|---|
| System PFMEA | Manufacturing process steps | processFailureMode | Risk Priority Number (RPN) | 16–20 modes |
| Control Plan | Process characteristics | controlPlanItem | Control method type | 10–25 items |
Risk Priority Number (RPN) = Severity × Occurrence × Detection
RPN Range: 1–1000 (lower values indicate lower risk)
RPN Thresholds:
• Low: RPN 1–40
• Medium: RPN 41–100
• High: RPN >100
FMEA Coverage Report
The FMEA Coverage Report identifies failure modes that lack detection strategies or risk mitigation.
| Metric | Description | Threshold |
|---|
| Detection ≥ 7 | Failure modes with insufficient detection capability | >6 |
| No Risk Control | Failure modes without linked risk control work items | Missing links |
| Unassigned AP | Failure modes without Action Priority classification | Blank/NA |
| Post-Mitigation High | Failure modes with post-mitigation AP/RPN still in high range | AP ≥ 200 or RPN > 100 |
Report Generation Properties
FMEA Report Dashboard Configuration
| Property | Type | Default | Description |
|---|
fmeaReportType | enum | designFmea | Report scope: designFmea (DFMEA), processFmea (PFMEA), or coverageGap |
failureModeQuery | Lucene | type:failureMode | Work item query filtering failure modes for the report |
severityField | string | severity | Custom field name storing Severity rating (1–10 scale) |
occurrenceField | string | occurrence | Custom field name storing Occurrence rating (0–10 scale) |
detectionField | string | detection | Custom field name storing Detection rating (0–10 scale) |
actionPriorityField | string | actionPriority | Custom field name storing calculated AP value |
riskControlLink | link role | mitigatedBy | Link role connecting failure mode to risk control |
preThreshold | integer | 200 | Action Priority high-risk threshold (pre-mitigation) |
postThreshold | integer | 200 | Action Priority high-risk threshold (post-mitigation) |
rpnLowThreshold | integer | 40 | RPN low-risk boundary |
rpnHighThreshold | integer | 100 | RPN high-risk boundary |
Risksheet Column Binding
FMEA data is edited through Risksheet documents. Column bindings map Risksheet cells to work item custom fields:
| Column Header | Work Item Field | Type | Visible In Report |
|---|
| Failure Mode | name | string | Yes (primary key) |
| Function / Subsystem | affectsFunction or affectsSubsystem | link | Yes (context) |
| Effects | effects | text | Yes (description) |
| Severity | severity | enum (1–10) | Yes (S component) |
| Occurrence | occurrence | enum (0–10) | Yes (O component) |
| Detection | detection | enum (0–10) | Yes (D component) |
| Action Priority | actionPriority | calculated | Yes (primary metric) |
| Risk Control | mitigatedBy | link | Yes (mitigation status) |
| Post-Mitigation AP | actionPriorityPost | calculated | Yes (residual risk) |
| Status | status | enum | Yes (workflow state) |
Velocity Macro Integration
FMEA reports use Nextedy Solutions Velocity macros for rendering:
#* Standard FMEA Report Header *#
#parse("nextedy_solutions.vm")
#nxDocHeaderGray("FMEA Reports", "AIAG-VDA Failure Mode Analysis", $headerColor)
#* Summary Statistics Cards *#
#set($dfmeaCount = $utils.findWorkItems("type:failureMode AND status:active"))
#set($pfmeaCount = $utils.findWorkItems("type:processFailureMode AND status:active"))
#nxSummaryCards([
{"label": "Design Failure Modes", "value": $dfmeaCount.size(), "icon": "warning"},
{"label": "Process Failure Modes", "value": $pfmeaCount.size(), "icon": "cog"}
])
#* RPN Classification Buckets *#
#nxRpnBuckets($dfmeaCount, "actionPriority", 50, 200)
FMEA Report Views and Navigation
FMEA Reports Landing Page
The FMEA Reports page serves as the navigation hub for all FMEA analysis:
| Section | Content | Link Target |
|---|
| Live Statistics | Real-time failure mode counts (DFMEA, PFMEA) | Automatic update via Lucene |
| Design FMEA Card | AIAG-VDA 2019 methodology overview, scope, AP classification | System DFMEA Report wiki page |
| Process FMEA Card | Manufacturing process failure analysis, RPN methodology | System PFMEA Report wiki page |
| Quick Links | FMEA Coverage Report, Risk Control Effectiveness, Control Plans | Related dashboard links |
title: "FMEA Reports"
icon: "warning"
cardLayout: "fluent-design-system"
statsAutoRefresh: true
refreshInterval: 300 # seconds
System DFMEA Report
System-level Design FMEA report showing failure mode distribution by severity and occurrence:
| Panel | Content | Update Frequency |
|---|
| Summary Statistics | Total failure modes, High/Medium/Low AP distribution | Real-time |
| Severity Distribution | Histogram of failure modes by Severity rating | On page load |
| Occurrence Distribution | Histogram of failure modes by Occurrence rating | On page load |
| Detection Gap Analysis | Failure modes with Detection ≥ 7 (high detection difficulty) | On page load |
| Critical Items Table | Failure modes with post-mitigation AP ≥ 200 (red alert) | Real-time |
| Risksheet Links | Direct links to System DFMEA Risksheet documents by subsystem | Manual |
System PFMEA Report
Process-level FMEA report with RPN classification and control plan linkage:
| Panel | Content | Update Frequency |
|---|
| Summary Statistics | Total process failure modes, RPN distribution (Low/Medium/High) | Real-time |
| Pre vs Post-Mitigation Comparison | Side-by-side RPN counts before and after controls | On page load |
| RPN Threshold Alert | Conditional warning if post-mitigation RPN >100 items exist | Real-time |
| Process Failure Modes Table | All processFailureMode items with linked process steps and control plans | On page load |
| Control Plan Navigation | Links to Control Plan Risksheet and Process Flow diagram | Manual |
FMEA Reporting Workflow
The FMEA lifecycle integrates multiple work item types and documents:
| Step | Action | Output |
|---|
| 1 | Select report scope | System/subsystem/component filter |
| 2 | Configure parameters | Date range, ASIL level, status filter |
| 3 | Generate report | Automated data collection and analysis |
| 4 | Review RPN distribution | Pre-action vs. post-action comparison |
| 5 | Identify high-risk items | Items exceeding RPN threshold |
| 6 | Export results | PDF or Excel output with charts |
| 7 | Track improvements | Action item closure and RPN trends |
Cross-Links to Related Pages
For deeper understanding of FMEA analysis in TestAuto2, see:
Report Export and Archival
FMEA reports are exported for regulatory documentation:
| Export Format | Use Case | Retention |
|---|
| PDF | Stakeholder review, traceability evidence | Permanent (ISO 26262 Part 8 audit trail) |
| HTML | Live dashboard snapshot, revision history | Per project policy (typically 5+ years) |
| CSV | Failure mode data import to external tools, trending analysis | Per project policy |
| Velocity Wiki | Version control in Polarion, approval workflow | Permanent (Polarion repository) |
All FMEA reports must be archived with date, author, and approval stamps for ISO 26262 Part 8 Clause 6 traceability documentation. Use Polarion’s document approval workflow to establish change baseline.
