First Edition, February 1993' Second Edition, February '1995' Third Edition, July 2001, Fourth Edition, June 2008 Copyright © 1993, © 1995, © 2001, © 2008 Chrysler LLC, Ford Motor Company, General Motors Corporation
The FMEA 4 th Edition is a reference manual to be used by suppliers toChrysler LLC, Ford Motor Company, and General Motors Corporation as a guide to assist them in the development of both Design and Process FMEAs, The manual does not define requirements; it is intended to clarify questions concerning the technical development of FMEAs, This manual is aligned with SAE ,11739,
Summary of Changes
4th editionFMEA Reference Mamllli
The DFMEA and PFMEA methodsdescribed in the 4'" edition FMEA Reference Manual include those associated with design at the system, subsystem, interface, and component level and the process at manufacturing and assembly operations,
• The formatting used in the 4 th edition is intended to provide easier reading, o An index is included, o [cons are used to indicate key paragraphs and visual cues are used,Additional examples and verbiage have been provided to improve the utility of the mauual and to provide a closer tie into the FMEA process as it develops, Reinforcement ofthe need for management support, interest, and review of the FMEA process and results, Define and strengthen the understanding of the linkage between DFMEA and PFMEA as well as defining the linkages to other tools, Improvements tothe Severity, Occurrence, Detection ranking tables so that they are Alternative methods are introduced that are currently being applied in industry, o Additional appendices which have example forms and special case application of FMEA, o The focus on the "standard form" has been replaced with several options that represent the current application of FMEA in industry, The suggestion that RPN not beused as the primary means for assessing risk. The need for improvement has been revised including an additional method, and the use of thresholds on RPN is clarified as a practice that is not recommended,
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Chapter I provides general FMEA guidelines, the need for management support and having a defined process for developing and maintaining FMEAs, and the need for continuousimprovement. Chapter II describes the general application ofthe FMEA methodology, which is common between DFMEA and PFMEA processes, This includes the planning, strategy, action plans, and the need for management support and responsibility in FMEAs, III focuses on DFMEA (Design Failure Mode Effects and Analysis), establishing the scope ofthe analysis, use of block diagrams, various types of DFMEAs,formation ofthe teams, basic procedure for analysis, action plans, and follow-up, alternatives to RPN, and connection to PFMEAs and validation plans.
Chapter IV focuses on PFMEA (Process Failure Mode Effects and Analysis), establishing the scope of the analysis, usc offlow diagrams, formation of teams) basic procedure for analysis, action plans, the connection to DFMEAs and thedevelopment of control plans. The have several examples of forms for DMFEA and PFMEA and addresses different applications and procedures for addressing design and process risk. The Snpplicr Quality Requirements Task Force would like to thank the following individuals, and their companies, who have contributed their time and efforts to the development ofthis edition of the FMEA Reference Manual: MichaelDown, General Motors Corporation Lawrence Brozowski, General Motors Corporation Hisham Younis, Ford Motor Company David Benedict, Chrysler LLC John FeghalL Chrysler LLC Michael Schubert, Delphi Rhonda Brender, Delphi Gregory Gruska, Ornnex Glen Vallance, Control Planning Initiatives Milena Krasich, Bose William Haughey, Relia'Irain This manual is a copyright of Chrysler LLC, Ford Motor Company...