Failure Mode and Effects Analysis (FMEA) is a crucial methodology in the automotive industry, yet it is riddled with complexities and challenges. In our latest webinar, we delved into the intricacies of FMEA standards with Hans Trunkenpolz, founder of ht+a. He provides a comprehensive overview of the existing standards and customer-specific requirements that make FMEA a convoluted yet indispensable tool for the automotive sector.
We begin by highlighting the confusion surrounding FMEA due to the existence of five recognized standards and additional customer-specific requirements. Despite introducing the harmonized AIAG-VDA standard, the lack of consensus among Original Equipment Manufacturers (OEMs) perpetuates confusion. The AIAG-VDA standard was supposed to bring about a unified approach, but its implementation has been inconsistent. FORD, for instance, requires multiple FMEA types, including foundation and family FMEAs, and the integration of software tools. On the other hand, Mercedes-Benz uniquely mandates the harmonized AIAG VDA version, while Volkswagen Group adheres strictly to VDA guidelines. Stellantis offers some flexibility but strongly recommends AIAG VDA. The historical efforts to harmonize American and German standards have been lengthy and fraught with challenges.
In the context of product development, robust design principles are paramount. Hans underscores the necessity of early involvement of production experts in the FMEA process to enhance product robustness. He discusses common pitfalls such as inadequate initial FMEA efforts and the detrimental impact of cost reduction on product robustness. The disconnect between design engineers and manufacturing operations exacerbates these issues. For instance, design engineers are often not allowed to see the production technologies used to manufacture the parts they design, leading to a lack of understanding of manufacturability constraints.
BMW's unique approach to FMEA and design responsibility is also explored. Hans explains the distinction between engineering-responsible or design-responsible suppliers and build-to-print suppliers. He stresses the importance of integrating the voice of the process (VOP) into product design to ensure that the manufacturing process is considered during the design phase. Challenges with simultaneous engineering teams and the implementation of BMW's group standards are highlighted, along with suggestions for improving transparency and communication.
We also discuss the variability in scoring criteria among different FMEA standards. The harmonized AIAG VDA approach, for example, prioritizes severity over occurrence and detection in assessing risks, which is a departure from the traditional Risk Priority Number (RPN) method used in other standards. The harmonized approach uses an Action Priority (AP) system, which factors in the severity of a potential failure mode more heavily than occurrence and detection. This shift in focus aims to ensure that the most critical risks are addressed first, improving overall product safety and reliability.
The episode also delves into the challenges faced by suppliers in meeting varied FMEA standards. Hans shares practical strategies for navigating these complexities, such as the importance of seeking waivers from OEMs and the need for robust documentation and software solutions to ensure consistency. He highlights the critical role of coherent documentation in meeting stringent requirements and avoiding discrepancies.
In summary, this webinar offers insights into the complexities and challenges of FMEA in the automotive industry. Whether you are a supplier, an OEM, or simply interested in automotive engineering standards, it provides valuable information and practical strategies to tackle the pervasive issues within FMEA implementation. By understanding the nuances of different FMEA standards and the importance of proactive communication, suppliers can better navigate this intricate landscape and enhance their compliance and product robustness.
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