Aerospace FMEA differs from automotive J1739. ARP5580, AS9100 expectations, FMECA criticality matrix, FRACAS integration, and audit documentation.
Five-step closure process with evidence templates, re-rating rules, and the connected artifacts auditors check after FMEA actions are implemented.
Prevention controls reduce occurrence; detection controls reduce detection ratings. The AIAG-VDA priority hierarchy and when each type is the right investment.
Severity 9-10 in FMEA designates Critical Characteristics. Control plan entries, Cpk targets, customer notification, and audit evidence required.
Apply FMEA to ISO 26262 safety analysis: failure mode categories, ASIL mapping, detection controls, and where FMEA ends and FMEDA begins.
IATF 16949 automotive FMEA requirements: Clause R15, what auditors verify across DFMEA, PFMEA, and Control Plan, and how to document compliance.
How to run productive FMEA review meetings: pre-meeting prep, role assignments, agenda structure, and tactics for resolving S/O/D rating disagreements.
Design FMEA vs process FMEA: scope, timing, and how DFMEA failure modes become PFMEA causes. AIAG-VDA linkage breakdown and APQP timing table.
Writing DFMEA failure modes correctly: verb-noun syntax, function-based framing, and the cause-mode-effect separation that audits actually test.
Why high RPN does not mean biggest risk in FMEA: how AIAG-VDA AP corrects the misranking, and how to interpret S=10 / low-O / low-D rows correctly.
Linking PFMEA to control plan and PFD: five shared identifiers, ECN cascade workflow, and the audit cross-reference test that catches mismatches.
How boundary diagrams and P-diagrams define DFMEA scope. Construction steps, how they feed Step 2 and Step 3, and the failure modes most teams skip.
How to update an FMEA after an ECN: scope mapping, re-rating S/O/D, cascading to PFD and Control Plan, and audit-ready version control.
Compares Excel, Google Sheets, Open FMEA, and trial tiers as free FMEA software. Verdict by audit context, with the IATF 16949 R15 risk most lists skip.
How medical device FMEA fits into the ISO 14971 risk management file: hazard vs failure mode, RMF structure, and why automotive AP tiers fail audits.
An AIAG-VDA FMEA template in Excel for manufacturing: column structure, RPN and AP lookup formulas, data validation, and when Excel breaks down.
How to prioritize FMEA action items when engineering time is tight: AP triage, effort-vs-impact matrix, and batching Mediums by shared cause.
Learn how to evaluate current controls and assign FMEA detection ratings consistently. Includes a structured decision path, 1-10 scale with control types, and a control upgrade path for improving detection.
Learn how to determine FMEA occurrence ratings using Cpk data, historical failure rates, or engineering judgment. Includes a complete 1-10 scale with Cpk equivalents and manufacturing examples.
Complete FMEA severity rating scale with 1-10 definitions anchored to specific manufacturing and assembly failure examples. Includes worked injection molding PFMEA example and team calibration techniques.
Walk through all seven steps of a process FMEA using the AIAG-VDA method with a real injection molding example. Covers structure analysis, function analysis, failure analysis, risk ratings, optimization, and results documentation.
Compare FMEA Action Priority (AP) and Risk Priority Number (RPN) side by side. Learn why the AIAG-VDA 2019 handbook replaced RPN, how the AP lookup table works, and a practical transition approach for your FMEA program.
Learn how to calculate Risk Priority Number (RPN) in FMEA with a full worked example from a manufacturing PFMEA. Covers severity, occurrence, and detection rating scales, common thresholds, and when to use RPN vs. AIAG-VDA Action Priority.