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Interesting Discussion New AIAG PFMEA Process - Excel Template Attached

The new AIAG manuals are definitely worth reading; there have been significant changes since the 1990s. Guidance on the occurrence and detection ratings is better, and they also look at severity ratings for the process (e.g. potential risk to workers, continuity of operations) as well as the product.


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Hello all,
can someone please explain what is the main reason to replace RPN with Action priority ? How Action Priority is better than RPN ?
Thank you in advance.
Hello all,
can someone please explain what is the main reason to replace RPN with Action priority ? How Action Priority is better than RPN ?
Thank you in advance.
RPN is the product of three ordinal numbers. A failure mode with severity = 10, occurrence 4 and detection 5 has a RPN of 200, as does one with S=4, O=5, and D=10. The latter can at most annoy the customer while the former can kill him. Action Priority gives the severity the biggest weight, followed by occurrence, and finally detection. This stresses that it is best to eliminate or mitigate the failure effect, next best to prevent it, and finally to detect it before it can actually cause trouble.

One thing I am uncomfortable with is the proposition that you can have a S=10 failure mode with a Low action priority with O and D ratings of greater than 1 (although they must be relatively low).


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hello again thanks for info.
at the company where I work we are far from using new PFMEA approach and far from replacing RPN with AP.

How exactly will this become mandatory? Maybe update of customer specific requirements ? Any thoughts about this ? How in the past such transition was managed ?

Pau Calvo

Starting to get Involved

I have been hearing the transition to AP for the last few years in some seminars regarding FMEA.
In my actual company, Tier 2, none of the customers have required the implementation yet but in a previous company that I have work a customer ask for this evaluation even before the last version of FMEA handbook was released.

It would depend of how many new projects, how many customers make the transition and how often you review and update the FMEA that you will reach the point to change the FMEA evaluation for all the customers.

My recommendation is to follow your customer requeriments and have a template prepared with the new evaluation method and a Action Plan of implementation.

This way you will not get surprises and your answer to your customer will be agile.


Stop X-bar/R Madness!!
Generally, you customers will tell you when they will begin demanding the 1st edition AIAG/VDA approach. However, you will want trained on it ahead of time, because the resources you will need to complete one is much, much greater and you won't want to struggle through it on your own with a deadline to submit closing in.


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thanks for answers
i think no new analysis on existing projects need to be done right ? Can you just carry on with current PFMEA and change the RPN with AP and mitigate risk for failures with high severity, occurrence and finally detection or you need to start from scratch with enterely new PFMEA ?
I also think the company should be informed well in advance if the customer is requesting risk analysis based on the new handbook for upcoming projects although customers not always care about their suppliers and might forget this "small" detail.
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