AIAG-VDA FMEA tutorial and completely filled FMEA
- Thread starter suchir912
- Start date
Johnnymo62
Haste Makes Waste
AIAG has training here: (FMEA) Failure Mode & Effects Analysis | AIAG
Sleepy Cat
Starting to get Involved
We were trained of AIAG VDA PFMEA, although not the site was introduced above. And Process Work Elements learned to think in terms of 4M.
However, as noted in Handbook (2nd Printing jul. 2022) 3.2.3, the number of categories may vary by company, and additional categories such as Method and Measurement should be acceptable.
Sure, it's not necessary to list in every category all the time, but we decided at certain Process Step we should mention Method.
For example, name the step "Mixing", because our actual step contains confidential information.
However, I don't know how to write the following items for "Method".
Is the below a correct?
Step2 Process Step; Mixing
- Process Work Element; Stirring speed according to the work instruction
Step3 Function of the Process Step; Aagitate powder uniformly
- Function of the Process Work Element; the work instruction instructs the procedure to achieve uniform mixing
Step4 Failure Mode (FM) of the Process Step; Uneven mixing
- Failure Cause (FC) of the Work Element; Incorrect or insufficient instructions, damaged or dirty, not near the operator
If I am wrong, please let me know specifically which step is wrong and how to fix it.
However, as noted in Handbook (2nd Printing jul. 2022) 3.2.3, the number of categories may vary by company, and additional categories such as Method and Measurement should be acceptable.
Sure, it's not necessary to list in every category all the time, but we decided at certain Process Step we should mention Method.
For example, name the step "Mixing", because our actual step contains confidential information.
However, I don't know how to write the following items for "Method".
Is the below a correct?
Step2 Process Step; Mixing
- Process Work Element; Stirring speed according to the work instruction
Step3 Function of the Process Step; Aagitate powder uniformly
- Function of the Process Work Element; the work instruction instructs the procedure to achieve uniform mixing
Step4 Failure Mode (FM) of the Process Step; Uneven mixing
- Failure Cause (FC) of the Work Element; Incorrect or insufficient instructions, damaged or dirty, not near the operator
If I am wrong, please let me know specifically which step is wrong and how to fix it.
Is this a general example or do you think it is specific and complete for the mixing step?
Some feedback: what is damaged and dirty? What isn’t near the operator? Aren’t there other causes? We would need specifics about the mixing equipment and process to add much.
Some feedback: what is damaged and dirty? What isn’t near the operator? Aren’t there other causes? We would need specifics about the mixing equipment and process to add much.
Sleepy Cat
Starting to get Involved
AndrewK, Bev D,
Thank you for your response.
I regret that I should have attached the picture from the beginning, too.
However, for some reason i am not able to insert the image. So, let's reproduce our FMEA with a simple table.
Assume the process of mixing powder with manpower. And, the mixing speed is written in the instruction document.
What we don't know is how to write the method (in highlighted red).
In Step 2, is it better to simply write "instruction document" only?
Or is it better to just write "mixing speed"?
The Process Function of Method in Step 3 must be explained in the phrase format of "do this" or "to this", is the subject at that time correct with "instruction document"?
Below is the answer to Bev D's question about FC in Step4.
The instructions are damaged or dirty and the operator cannot read them.
The operator does not know the mixing speed because the instructions are not near him.
Thank you for your response.
I regret that I should have attached the picture from the beginning, too.
However, for some reason i am not able to insert the image. So, let's reproduce our FMEA with a simple table.
Assume the process of mixing powder with manpower. And, the mixing speed is written in the instruction document.
What we don't know is how to write the method (in highlighted red).
In Step 2, is it better to simply write "instruction document" only?
Or is it better to just write "mixing speed"?
The Process Function of Method in Step 3 must be explained in the phrase format of "do this" or "to this", is the subject at that time correct with "instruction document"?
Below is the answer to Bev D's question about FC in Step4.
The instructions are damaged or dirty and the operator cannot read them.
The operator does not know the mixing speed because the instructions are not near him.
| STRUCTURE ANALYSIS (Step 2) | <- | <- | <- | FUNCTION ANALYSIS (Step 3) | <- | <- | <- | FAILURE ANALYSIS (Step 4) | <- | <- | <- |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1.Process Item System, Subsystem, Part Element or Name of Process | 2. Process Step Station No. and Name of Focus Elem | 3. Process Work Element 4M Type | <- | 1.Function of the Process Item Function of System, Subsystem, Part Element or Process | 2. Function of the Process Step and Product Characteristic (Quantitative value is optional) | 3. Function of the Process Work Element and Process Characteristic | <- | 1. Failure Effect (FE) to the Next Higher Level Element and/or End User | Severity (S) of FE | 2. Failure Mode (FM) of the Focus Element | 3. Failure Cause (FC) of the Next Lower of Characteristic |
| Mixing line | [01] Mixing of powder | Material | Flour | Make pancake dough | Aagitate powder uniformly | Material | Uneven mixing | ||||
| Material | Sugar | Material | |||||||||
| Machine | Bowl | Machine | |||||||||
| Machine | Whisk | Machine | |||||||||
| Method | Mixing speed according to the work instruction | Method | The work instruction document instructs the procedure to achieve uniform mixing | The work instruction document is incorrect or insufficient instructions, damaged or dirty, not near the operator | |||||||
| Man | Operator | Man | |||||||||
| Measurement | Cup | Measurement | |||||||||
| Environment | Room humidity | Environment | |||||||||
| [02] Mixing of liquid |
HI ! now it is more clear. Question is - does operator able to control mixing speed? how he can measure it?
so in Structure analysis we should answer what this elements involved in process. In case of Method - i would put instead "Mixing speed according to the work instruction "- just " mixing technique" or somethig like that.
In Function analysis we should answer - what elements should do to achieve product requierements (basically it is process parameters there)- instead "The work instruction document instructs the procedure to achieve uniform mixing" we can put like " Establish proper mixing speed or mixing route (clockwise or opposite if it does matter) according Work instruction #12345"
so in Structure analysis we should answer what this elements involved in process. In case of Method - i would put instead "Mixing speed according to the work instruction "- just " mixing technique" or somethig like that.
In Function analysis we should answer - what elements should do to achieve product requierements (basically it is process parameters there)- instead "The work instruction document instructs the procedure to achieve uniform mixing" we can put like " Establish proper mixing speed or mixing route (clockwise or opposite if it does matter) according Work instruction #12345"
Sleepy Cat
Starting to get Involved
Hi, I understand little by little.
For example, Work instruction #12345 should say as "mixing technique"; "stir 5 times clockwise along the edge of the bowl over 3 seconds."
In that case, should we write like the table below?
Structure Analysis - "1 stir per 3 seconds by 5 times - clockwise", Function Analysis - "Establish proper mixing speed according to work instruction #12345"
Is this style of writing "can" or "should"?
Also, is there anything that should be fixed in FC?
Work instruction #12345 has incorrect or outdated instructions (Not updated) - as "1 stir per 1 sec by 5 times".
Work instruction #12345 has the correct information as "1 stir per 3 seconds by 5 times", but the printed document is damaged or dirty, so the operator cannot read it.
Work instruction #12345 has the correct information and the printed document is in good condition, but it is not in a place where the worker can read it.
For example, Work instruction #12345 should say as "mixing technique"; "stir 5 times clockwise along the edge of the bowl over 3 seconds."
In that case, should we write like the table below?
Structure Analysis - "1 stir per 3 seconds by 5 times - clockwise", Function Analysis - "Establish proper mixing speed according to work instruction #12345"
Is this style of writing "can" or "should"?
Also, is there anything that should be fixed in FC?
Work instruction #12345 has incorrect or outdated instructions (Not updated) - as "1 stir per 1 sec by 5 times".
Work instruction #12345 has the correct information as "1 stir per 3 seconds by 5 times", but the printed document is damaged or dirty, so the operator cannot read it.
Work instruction #12345 has the correct information and the printed document is in good condition, but it is not in a place where the worker can read it.
| STRUCTURE ANALYSIS (Step 2) | <- | <- | <- | FUNCTION ANALYSIS (Step 3) | <- | <- | <- | FAILURE ANALYSIS (Step 4) | <- | <- | <- |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1.Process Item System, Subsystem, Part Element or Name of Process | 2. Process Step Station No. and Name of Focus Element | 3. Process Work Element 4M Type | <- | 1.Function of the Process Item Function of System, Subsystem, Part Element or Process | 2. Function of the Process Step and Product Characteristic (Quantitative value is optional) | 3. Function of the Process Work Element and Process Characteristic | <- | 1. Failure Effect (FE) to the Next Higher Level Element and/or End User | Severity (S) of FE | 2. Failure Mode (FM) of the Focus Element | 3. Failure Cause (FC) of the Next Lower of Characteristic |
| Mixing line | [01] Mixing of powder | Method | 1 stir per 3 seconds by 5 times | Make pancake dough | Aagitate powder uniformly | Method | Establish proper mixing speed according to work instruction #12345 | Uneven mixing | The work instruction document is incorrect or insufficient instructions, damaged or dirty, not near the operator |
Is this a real process or an exercise? I see “make pancake dough”…it is always better to learn with real examples from your work. Simplistic examples are good for introducing a complex topic in a classroom environment but after that we need to work with real world processes.
For example if this were a real manufacturing process I would be asking you such things as:
What is used to stir the powder?
Is the stirring manual or machine controlled?
What is used to measure the correct amount of powder? Is the powder measured by weight or volume? Is the powder sifted or in a state of natural settling?
Each of these matters. They are far more important than a dirty work instruction.
For example if this were a real manufacturing process I would be asking you such things as:
What is used to stir the powder?
Is the stirring manual or machine controlled?
What is used to measure the correct amount of powder? Is the powder measured by weight or volume? Is the powder sifted or in a state of natural settling?
Each of these matters. They are far more important than a dirty work instruction.
in structure analysis you need to mention name of element in your system structure.
It is Like - Mixing line(system) consist of : Man element- operator, or whatever position it called. Machine element- bowl, Macine element whisk etc. and method itself- name of method- like "manual steering method" for example. then in functional analysis we explain that our manual steering method do- it establish (or declare, dont know what word is better to use, because i'm not native English speaker) proper speed according document etc. at least i see it like that and that logic been used in the software in which i was teached to work. Regarding FC there might be more- depending on what requierements to work instruction or method itself you have. Logic is Failure- is opposite of product requierement. Failure cause is opposite of requirement of process element. How detailed list of requierements will be - is a question of team analysis.
regarding style of writing in Function analysis: Handbook says
it is better to read explanations cmpletley to all Process FMEA strting from page 83
Last edited:
