7-step approach
Planning and preparation, structure analysis, function analysis, failure analysis, risk analysis, optimisation, results documentation.
Greece Lean Six Sigma, Automotive handbook
AIAG and VDA FMEA Handbook: Failure Mode and Effects Analysis
The joint AIAG and VDA handbook (2019) harmonised North American and German FMEA practice, with a 7-step approach and Action Priority in place of RPN.
AIAG and VDA FMEADFMEA and PFMEAAction Priority
Preventing failures before they happen
What it is and why it matters
FMEA is a systematic analysis that identifies potential failure modes of a product or process, their effects and causes, and prioritises preventive actions.
The AIAG and VDA handbook replaced the AIAG 4th edition FMEA manual and VDA Volume 4 as a common basis for automotive suppliers, and it is increasingly used in other industries too.
Customer-specific requirements may add conditions to how the handbook is applied.
AIAG and VDA FMEA
Core subject areas
Action Priority (AP)
Action Priority tables replace the risk priority number (RPN).
Revised tables
New severity, occurrence and detection tables.
DFMEA and PFMEA
Analysis in product design and in manufacturing processes.
FMEA-MSR
A supplementary chapter on monitoring and system response in operation.
GLSS
Practical GLSS application guide
1
Define the scope, team and boundaries of the analysis.
2
Analyse structure and functions before failures.
3
Link failure modes, effects and causes.
4
Evaluate with the AP tables and assign actions with owners and dates.
5
Link results to the control plan and review the FMEA at every change.
These steps are a GLSS application approach, not necessarily mandatory steps of the publication.
Illustrative example
An assembly line updates its PFMEA with the 7-step approach. High-priority AP actions are linked to the control plan and reviewed after each process change.
The example is illustrative and does not describe a real client.
How Greece Lean Six Sigma can help
GLSS trains teams in FMEA using the AIAG and VDA approach and links it to Lean Six Sigma projects and control plans.
Frequently asked questions
Is RPN still used?
In the AIAG and VDA handbook, prioritisation uses Action Priority. Some customers or sectors may still use RPN, so check their requirements.
Is it only for automotive?
It was written for automotive, but the method applies in other industries and in services.
Official publications and further reading
An independent GLSS educational guide, not a reproduction of the publication or an official interpretation by its publisher. Training does not automatically confer independent certification or accreditation. Verify current editions and applicable requirements with the official publisher. Last checked: October 2026.
Greece Lean Six Sigma
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