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Move from FMEA 3 rd to 4 th Editions

Beginning November 1, 2008, the Chrysler, Ford, and GM, Failure Mode Effects Analysis Reference anual, 4th edition, available from AIAG, will supersede the 3rd edition. The 4th edition of the FMEA Reference Manual expands on the efforts of the 3rd edition by treating the entire FMEA process rather than just the forms in order to minimize the improper uses and implementation of the FMEA, such as:

  • Column shifting: placing information in the wrong columns thus hindering the analysis and product / process improvement efforts
  • Deflation of the RPN to obtain an arbitrarily set threshold
  • Sole reliance on the RPN in the evaluation of risk priorities and improvement actions
  • Focusing only on the completion of the FMEA form and not on the knowledge contained therein
  • Lack of understanding of the role of the FMEA process throughout the APQP phases including continual improvement during production; i.e., looking at the FMEA as a static document necessary only for PPAP approval.

The 4th edition also contains discussion which will allow organizations with a mature FMEA process to go beyond the basic implementation and not be subject to nonconformances by auditors who only have a cursory knowledge of the FMEA process or attempt to audit to the manual as a standard.

Overview:

3rd edition 4thedition
Focus How to fill out a standard DFMEA and PFMEA form How to develop and document a FMEA with emphasis on DFMEA and PFMEA
APQP relationships Not addressed Addressed
FMEA development process Not addressed  Addressed
Prerequisite activities Not addressed Addressed 
Documentation  Oriented towards a single form  Minimal elements to be documented identified (carry over
from 3rd edition form). Alternate forms allowed and examples given.
Documentation DFMEA and PFMEA element discussions not consistent DFMEA and PFMEA element discussions made consistent with uniqueness’ identified.
S, O, D rankings Consistent with current SAE J-1739 Consistent with new SAE J-1739 being developed
RPN Only risk analysis metric discussed Default risk analysis metric is RPN but allows alternate analysis acceptable by the customer. Exclusive use of RPN to determine action priority is not recommended
RPN  No discussion on thresholds The use of an RPN threshold is not considered an acceptable practice for determining the need for recommended actions.
Linkages Not addressed Addressed
Examples Single example for DFMEA and PFMEA Multiple examples and graphics used to communicate concepts.

Table of Contents:

3rd edition 4th edition Comments 
General Information
  • Overview
  • What Is an FMEA
  • Manual Format
Chapter I GENERAL FMEA GUIDELINES
  • Introduction
    • FMEA Process 
    • Purpose of Manual
    • Scope of Manual 
  • Organization and Management for FMEA
  • Product and Process Development Process
  • Due Diligence
  • On-going Maintenance
Expanded to include prerequisites and
considerations for the entire FMEA process.
  • FMEA Implementation
  • Follow Up 
Chapter II  GENERAL FMEA Strategy, Planning, Execution
  • Introduction
  • Basic Structure
  • Methodology
  • Management Responsibility
Expanded to include the entire FMEA process. This section provides the general foundations for FMEAs including those other than Design and Process. It also provides a pedagogical tool to assist in education and training for the evelopment of FMEAs.
Design FMEA
  • Introduction
    • Customer Defined
    • Team Effort
  • Development of  a Design FMEA
    • Header elements
    • Body elements
  • Follow-Up Actions 
Chapter III DFMEA Design Failure Mode and Effects Analysis
  • Introduction
    • Customer Defined
    • Team Effort
    • Manufacturing, Assembly and Serviceability Considerations
Development of a Design FMEA
  • Prerequisites
    • Block (Boundary) Diagrams
    • Parameter (P) diagrams
    • Other Tools and Information Sources
    • Evaluation of the functional requirements and Interface diagrams
    • Interface diagrams
    • Team
  • Design FMEA Form Information
    • Header
    • Body
  • Follow-Up Actions
  • Maintaining DFMEAs 
  • Leveraging DFMEAs
  • Linkages
    • Design Validation Plan & Report (DVP&R)
    • PFMEA
    • DFMEA Process Mapped to APQP or product Development Process
New: Highlighted areas  The form information is presented as minimal elements necessary for an FMEA rather than requiring a specific form be
used as in the 3rd edition. The description of the minimum information required expands on that in the 3rd edition but was made consistent with that in the Process FMEA section
Process FMEA
  • Introduction
    • Customer Defined
    • Team Effort
  • Development of a Process FMEA
    • Header elements
    • Body elements
  • Follow-Up Actions
Chapter IV PFMEA Process Failure Mode and Effects Analysis
  • Introduction
    • Customer Defined
    • Team Effort
    • Design Considerations
Development of a Process FMEA
  • Prerequisites 
  • Process FMEA Form Information
    • Header
    • Body
  • Follow-Up Actions
  • Linkages
    • To other FMEA related Documents
    • To DFMEA
    • To Control Plan
New: Highlighted areas The form information is presented as minimal elements necessary for an FMEA rather than requiring a specific form be
used as in the 3rd edition. The description of the minimum information required expands on that in the 3rd edition but was made consistent with that in the Design FMEA section
APPENDICES
  • Design FMEA Quality Objectives
  • Process FMEA Quality Objectives
  • Design FMEA Block Diagram Example
  • Standard Forms for Design FMEA
  • Design FMEA Example
  • System FMEA
  • Standard Forms for Process FMEA
  • Process FMEA Example
  • Suggested PFMEA Occurrence Evaluation
  • Criteria With Ppk Values
  • Glossary
APPENDICES Appendix A: Sample Forms
  • DFMEA Forms
  • PFMEA Forms
Appendix B System Level FMEAs
Appendix C: 
  • Alternative Risk Analysis
Appendix D: 
Alternative Techniques
  • Fault Tree Analysis, (FTA) 
  • FMECA
  • DRBFM
Glossary
References 
Index
New: Highlighted areas Removed: cyan highlighted area – Sample forms include forms consistent with 3rd edition as well as examples of forms with additional information elements. Occurrence values are related to special causes not common cause variation; PPAP requirement focuses on common cause
variation