Have You Implemented the Updated FMEA Requirements from the Latest Ford CSR?

The Ford IATF 16949 Customer Specific Requirements (CSR) were updated in November of 2021 with several important changes that became effective as of January 03, 2022 and were required to be implemented by July 1, 2022 for all programs that have not completed job 1 by that date.  Below are the noteworthy additions to the latest CSR:

  • The need for organizations to develop Foundation FMEAs
    • These act as a baseline or template for every type of process that an organization might have and incorporates known failures, causes, effects, controls, lessons learned, etc.
    • These must have linkage to the Part FMEAs – if changes are made to these baseline Foundation FMEAs, for instance, it must result in a change to the affected Part FMEAs
    • Foundation FMEAs must exist for all forward model programs which have not completed job 1 by July 1, 2022, with both foundation and part FMEAs also being available in FMEA software by July 1 – see the next point below
  • The need for using FMEA software – gone are the days of Excel FMEAs
    • Organizations will need to have evidence of use of FMEA software that can link Foundation FMEAs with Part FMEAs and control plans, with the output being in an acceptable format – i.e. in accordance with the Ford FMEA Manual or the AIAG & VDA FMEA Handbook
    • Like the note above, FMEA software is to be in place and include these Foundation FMEAs and Part FMEAs – linked to control plans and other relevant documents – on July 1st, 2022 for all programs that have not completed job 1 by that date
  • The need for organizations to complete Reverse FMEAs (RFMEA) after a program launch
    • These are activities in which cross-functional teams will work with operators and Operations personnel to evaluate a process after launch to try to find new failure modes, beat error-proofing, etc. so that the PFMEA and potentially the Foundation FMEA can be strengthened by failure modes and causes that were not initially considered
    • Organizations will need to have evidence of RFMEA activity by July 1, 2022 for programs that have not completed job 1 by that date

Do you currently have FMEA software in place?  Are you able to create Foundation FMEAs that serve as benchmarks for consistently and align with Part FMEAs and control plans?  As these moves show an OEM shift toward AIAG-VDA FMEA methodology, are you prepared to make the transition?

FMEAQuest helps you completely manage all of your Design FMEAs, Process FMEAs and Control Plans and a provides automatic linkages across the entire process, including special characteristic designations.  When you make a change in one area, it automatically drives the required changes across the entire process. As you build an FMEA, the Control Plan is automatically created.  With the additional abilities to create family and foundational FMEAs and a completely rebuilt risk analysis to effectively identify action priorities, you’ll easily meet the new Ford CSR requirements and be prepared to transition from AIAG to the VDA method.

Challenges Addressed

  • Design FMEAs, Process FMEAs, Control Plans, impacted documents and procedures are all disconnected
  • Lack of transparency, consistency and discipline in creating and managing FMEAs
  • Difficult to determine the latest updated version of FMEA and control plan
  • Poor process for ensuring any change is driven across all impacted documentation and processes
  • Little control over who is making changes to FMEAs and Control Plans
  • Hard to impossible to manage changes required across Product Families
  • Non-conformances in audits for FMEA and Control Plan management
  • No dashboard to provide all FMEAs in one place