Quality & InspectionFree referencePDF, Excel, Word export

AIAG-VDA FMEA Action Priority Reference

The AIAG-VDA FMEA handbook, published in 2019, harmonised the US and German approaches into one seven step method and introduced action priority in place of RPN. This reference lists the steps, what H, M and L mean, and how the method connects to the control plan.

Download:

Topic	Group	What it means	Practical note
Step 1 Planning and preparation	7 steps	Define FMEA scope, team, timing, tools and the 5Ts: intent, timing, team, tasks, tools	Agree scope and boundaries with the customer before rating anything
Step 2 Structure analysis	7 steps	Break the system into structure elements and show how they connect	Use a structure tree or block diagram, or the process flow for a PFMEA
Step 3 Function analysis	7 steps	Describe the functions of each element and their requirements	Write each function as verb plus requirement
Step 4 Failure analysis	7 steps	Build the failure chain: failure effect, failure mode and failure cause	Keep effect, mode and cause in separate, linked columns
Step 5 Risk analysis	7 steps	Rate severity, occurrence and detection, then assign action priority	Rate against agreed criteria tables, not gut feel
Step 6 Optimization	7 steps	Plan actions, assign responsibility, track completion and re-evaluate risk	Re-rate only after actions are implemented and effective
Step 7 Results documentation	7 steps	Communicate the results and conclusions of the FMEA	Summarise open actions and special characteristics for the control plan
Action priority H (High)	Action priority	Highest priority for action	Team must identify an appropriate action to improve controls or justify why current controls are adequate
Action priority M (Medium)	Action priority	Medium priority for action	Team should identify actions, or may justify why current controls are adequate
Action priority L (Low)	Action priority	Low priority for action	Team could identify actions to improve prevention or detection, but is not required to
Severity 1	Action priority	No discernible effect	In the AP table a severity of 1 is rated Low
Severity 9 and 10	Action priority	Potential effect on safety or regulatory compliance	Treat as high attention even when O and D are moderate, and check the handbook table
AP replaces RPN	AP vs RPN	AP is looked up from a table of S, O and D combinations, not multiplied	Do not convert AP to a number or set an RPN threshold on top of it
Why RPN was dropped	AP vs RPN	Multiplication gives equal weight to S, O and D and hides severity	AP weights severity first, then occurrence, then detection
Rating criteria tables	Ratings	Severity, occurrence and detection criteria are defined per FMEA type (DFMEA, PFMEA, FMEA-MSR)	Adopt the handbook tables or document your own company tables
FMEA-MSR	Ratings	Supplemental FMEA for Monitoring and System Response, covering diagnostics in operation	Used for systems that monitor faults and respond while running
Special characteristics	Outputs	Characteristics needing special control, identified from FMEA results	Carry them into the control plan and drawings
Link to control plan	Outputs	PFMEA prevention and detection controls feed the control plan columns	Keep both documents revised together
Foundation and family FMEA	Reuse	Reusable base FMEAs for common elements or product families	Reduces rework but each project must check applicability
Actions and effectiveness	Outputs	Each action has an owner, target date, status and evidence of effectiveness	Close only with proof, such as test data or process capability

This is a study aid that summarises the structure of the method. The exact action priority tables of S, O and D combinations are published in the AIAG and VDA FMEA Handbook (2019). Use the official tables for customer submissions.

Move from RPN to action priority

Optional: talk through converting legacy FMEA records to the AIAG-VDA structure.

Optional. The tool and every export work without this. No spam.

How to use this reference

Search for a step, term or topic using the search box, or scroll the groups. Use it as a briefing sheet before an FMEA workshop, or paste the rows into your FMEA procedure to train new team members. It describes the structure of the method in plain words and points you to the official handbook for exact table values. Export it to Excel if you want to add your own company notes.

The seven steps in practice

The first three steps set the stage: planning, structure analysis and function analysis. Step 4 builds the failure chain, the heart of the document, where effects, modes and causes are linked. Step 5 rates risk and assigns action priority. Step 6 drives optimization actions and re-evaluation, and step 7 documents and communicates results. Teams that skip steps 1 to 3 usually produce FMEAs that are long but disconnected from the real design or process.

Action priority versus RPN

RPN multiplies three ratings, so a severity 10 with low occurrence can score lower than a trivial but frequent issue. Action priority uses a lookup of each S, O and D combination and returns High, Medium or Low, weighting severity first. The result tells the team how strongly an action is expected, not a number to compare across projects. If a customer still asks for RPN, show both, but base decisions on AP.

Common mistakes

Do not copy an AP table from the internet without checking it against the handbook, as copies often contain errors. Avoid treating Low as ignore: it means optional action, and any severity 9 or 10 deserves explicit review. Keep rating criteria consistent across the whole FMEA and record which criteria set you used. In your quality system, version the FMEA with the part or process revision so audits can trace decisions.

Frequently Asked Questions

Do I have to use action priority?

If a customer requires the AIAG-VDA method, yes, as it replaced RPN-based thresholds. Other customers may still accept RPN. Check the customer specific requirements in your contract or quality manual.

Where do I find the official AP table?

In the AIAG and VDA FMEA Handbook, first edition 2019, available from AIAG and VDA QMC. This page does not reproduce it, to avoid errors and respect the publisher.

Is severity 1 always Low priority?

Yes, in the handbook action priority tables a severity of 1 is rated Low regardless of occurrence and detection, because there is no discernible effect.

What is FMEA-MSR?

Monitoring and System Response FMEA is a supplement that analyses diagnostic monitoring and the system reaction to detected faults while the product is operating, used mainly for electronic and safety related systems.

If you want FMEA, control plans and ERP routings kept in sync, Netray can discuss how that could work in your stack. The reference above is free with no sign-up.

Talk to an Expert Explore More Free Tools

Related Tools

Quality & Inspection

More Quality & Inspection tools

See all

Back to All Tools