FMEA Generator

The FMEA generator extracts process steps and functions from your inputs, drafts plausible failure modes, effects and causes, and produces a structured AIAG-VDA matrix. The engineering team then moderates the rows, sets Severity / Occurrence / Detection, and the backend resolves Action Priority.

Most teams start with a spreadsheet template inherited from a previous project. It looks workable for one FMEA, then breaks the moment the team grows or a customer audit is announced. The failure pattern is always the same.

• Version control. "FMEA_final_v3_rev_after_meeting.xlsx" is not an audit trail. There is no reliable way to answer "what did we approve and when".
• Audit traceability. Reviewers cannot see who changed a rating or why. Inputs, controls and decisions are scattered across emails and chats.
• AP calculation mistakes. The AIAG-VDA Action Priority table is not a single formula — most templates fall back to RPN or implement AP partially. A 10-2-2 safety failure ends up as "Low" because the spreadsheet only multiplies.
• Collaboration. Two reviewers cannot edit the same matrix at the same time without overwriting each other. Cross-functional sessions degrade into screen-share marathons.
• Consistency. Severity scales drift between projects. Detection ratings inflate because no one defines what "automated" actually means.

See common FMEA mistakes for the engineering side of the same problem.

1. Inputs. Upload your process flow, drawings or a previous FMEA. Qhubio extracts steps, functions and known controls.
2. AI-assisted draft. The system proposes failure modes, effects and causes as a structured matrix — never as free-form prose.
3. Engineering moderation. The team reviews each row, adjusts wording, removes false positives, and confirms the controls actually in place.
4. Deterministic AP. Severity, Occurrence and Detection are rated once; Action Priority is calculated by the backend using AIAG-VDA 2019 rules. The math is never up to the spreadsheet.
5. Approval. Reviewer and approver sign off; the version is frozen and stored with input and output snapshots.
6. Export. One-click Excel and PDF for the customer file, the audit binder, or the Control Plan handoff.

• AIAG-VDA alignment. 7-step structure enforced from start to handoff.
• Action Priority engine. H / M / L calculated deterministically — Severity always dominates.
• PDF export. Customer-grade layout with revision history.
• Excel export. Three tiers (Basic / Advanced / Pro) for engineering, audits and OEM submissions.
• Team collaboration. Multiple reviewers, role separation between author, reviewer and approver.
• Version history. Every generation stores its inputs and outputs.
• Multi-language UI. EN, CZ, DE, FR, SK for cross-site teams.

• Automotive Tier-1 suppliers: PPAP-grade PFMEAs with AIAG-VDA AP, ready for OEM audits.
• CNC machining shops: Tool wear, dimensional drift and inspection capability handled as standard rows. See the worked example.
• Electronics manufacturing: Solder, AOI and ICT controls written as detection-by-design, not as inspection-only.
• Assembly operations: Poka-yoke and torque verification linked to detection rating.
• Medical devices: Risk file alignment between FMEA and ISO 14971 hazard analysis.
• Design engineering: DFMEAs that drive verification & validation, not paperwork.

See PFMEA CNC machining example for a realistic generator output after engineering moderation, and more worked examples across industries.

• Process flow diagrams (PFD). Best single input — gives the generator the step sequence and characteristics.
• Drawings & specs. Tolerances and special characteristics seed the failure modes.
• Prior FMEAs (Excel, PDF). Used to extract structure and known failure modes; ratings are not carried over by default.
• A written process description. Works when documentation is thin; quality scales with specificity.

• A full AIAG-VDA matrix ready for engineering moderation.
• Per-row evidence quotes linking each failure mode back to the source document, so the reviewer can verify the claim.
• Confidence indicator on each generated row — Low / Mixed / Good — based on how grounded the draft is in the inputs.
• Excel and PDF exports after moderation and approval.

• The generator does not assign Severity, Occurrence or Detection — engineers do.
• It does not know shop-floor reality; failure modes specific to a fixture or operator practice need to be added.
• Generic causes ("operator error") are forbidden by AIAG-VDA and must be rewritten — see common mistakes.
• Cross-FMEA learning is not automatic; institutional memory still lives in the reviewer.

• Standing up a first FMEA for a new product launch without 3 weeks of workshops.
• Migrating an Excel FMEA library into a structured AIAG-VDA format.
• Refreshing a stale PFMEA after a process change without rebuilding from scratch.
• Generating a PFMEA draft before a customer audit, then moderating in a single working session.

• AIAG-VDA 7-step process — the methodology applied end-to-end.
• Action Priority guide — how the AP decision actually works.
• Severity, Occurrence and Detection rating guides.
• FMEA → Control Plan linkage — what flows downstream.
• PFMEA CNC example and more worked examples.
• Audit readiness checklist.