FMEA Template: How to Build DFMEA and PFMEA Tables
What is FMEA?
FMEA (Failure Mode and Effects Analysis) systematically identifies potential failure modes of a product design or manufacturing process, assesses their risk and defines preventive actions. The AIAG-VDA FMEA handbook emphasizes a seven-step method (planning, structure analysis, function analysis, failure analysis, risk analysis, optimization and documentation) and uses Severity S, Occurrence O, Detection D and Action Priority AP instead of the old RPN ordering. FMEA is the source input for APQP, PPAP and control plans, and is a key document reviewed in IATF 16949 audits.
When to Use It
Use it during new product or process development, after design or process changes, and when new customer complaints or 8D outcomes require an update. It is also expected evidence in IATF 16949 system audits. FMEA is not a one-time file: review and update it whenever the process or field feedback changes.
How to Use It (Step by Step)
Choose the DFMEA or PFMEA template, then fill the columns in order: structure, function, failure mode, effect and cause. Rate S, O and D per row; the tool automatically calculates RPN = S × O × D and suggests the AIAG-VDA action priority (H/M/L), highlighting high-priority items. Define prevention and detection actions for high-priority items, then re-score after verification to close the loop.
Key Formulas / Example
RPN = S × O × D, with each rating on a 1-10 scale; the AP table in AIAG-VDA maps S, O and D combinations to High, Medium or Low priority. For example, S = 9, O = 4 and D = 3 give RPN = 108 and an AP of High, meaning action is required. High-risk failures identified in FMEA must be mapped to control methods in the control plan so the controls reach the shop floor.