AIAG Classic — Beta

IsometricFMEA

A free, browser-based Process FMEA tool for manufacturing and quality teams. Build your PFMEA, manage reusable libraries, and export clean reports — everything stays on your machine.

Your library is pre-loaded with automotive starter content. Customize it in the Libraries section.

Project Header Information
Part Name
Part Number
Model Year / Program
Process / Operation
Prepared By
Core Team
Customer
Supplier / Plant
FMEA Date
Revision Level
Revision Date
Confidentiality
AIAG Severity / Occurrence / Detection Rating Guide

Severity (S)

10Hazardous — without warningSafety / regulatory
9Hazardous — with warningSafety / regulatory
8Very HighVehicle inoperable
7HighVehicle operable, degraded
6ModerateComfort / convenience impaired
5LowComfort / convenience reduced
4Very LowFit / finish / squeak / rattle
3MinorNoticed by most customers
2Very MinorNoticed by discriminating customers
1NoneNo effect

Occurrence (O)

10Very High>1 in 2
9Very High1 in 3
8High1 in 8
7High1 in 20
6Moderate1 in 80
5Moderate1 in 400
4Low1 in 2,000
3Low1 in 15,000
2Very Low1 in 150,000
1RemoteFailure unlikely

Detection (D)

10Absolute UncertaintyNo known control
9Very RemoteVisual inspection only
8RemoteVisual / tactile inspection
7Very LowDouble visual inspection
6LowControl chart (SPC)
5ModerateVariable gauging
4Moderately HighAttribute gauging (go/no-go)
3HighError detection / 100% auto-inspect
2Very HighError prevention / mistake proof
1Almost CertainCannot make nonconforming part

RPN Thresholds (AIAG Classic): RPN = S × O × D (max 1000). High risk: RPN ≥ 200 or any Severity ≥ 9 — immediate action required. Medium risk: RPN 100–199 — action recommended. Low risk: RPN < 100 — monitor and review. Note: RPN alone should not be the sole decision criterion — high Severity scores always require attention regardless of RPN.

Failure Modes Library
Effects of Failure Library
Causes of Failure Library
Prevention Controls Library
Detection Controls Library
Special Characteristics Library