SSI Technologies: Mastering the harmonized AIAG & VDA FMEA

Background

Failure Mode and Effects Analysis (FMEA) is a systematic method for identifying and preventing potential failures in products and processes. The harmonized AIAG & VDA FMEA methodology, introduced in 2019, combines previous standards from the American AIAG (Automotive Industry Action Group) and the German VDA (Verband der Automobilindustrie). This unified approach aims to enhance risk assessment, improve consistency, and ensure better quality management in the automotive industry.

Hynek Zeman, a Process Engineering Manager at SSI Technologies, has been pivotal in the company’s successful implementation of the harmonized AIAG & VDA FMEA methodology.  “As a company, we previously relied on Excel for FMEA documentation,” Hynek explains. “However, many of our large customers use very expensive specialized software for FMEAs. We recognized that we needed a better solution.” This understanding prompted SSI Technologies to adopt the harmonized FMEA standard early on. “The advantage of AVIX is its standardized template, which minimizes the risk of errors and ensures consistency across projects.”

The Challenge

Before implementing AVIX FMEA, SSI Technologies faced significant challenges. The use of Excel resulted in manual errors and inconsistencies. “Excel is primarily a table editor,” Hynek points out. “While it allows for formulas and macros, it lacks control over formatting. If two people complete the same task in Excel, the results can vary significantly.” This lack of standardization made it crucial for the company to find a more structured solution.

The Solution

After evaluating various FMEA software options, SSI Technologies chose AVIX FMEA. “AVIX began with FMEA in earlier versions, but with the new harmonized methodology, both US and European groups have come together on a unified approach,” Hynek states. “We are now successfully using this methodology across our projects.”

With AVIX, SSI Technologies adopted the harmonized FMEA standard for all new projects while retaining older projects within the AVIX system. “One of the biggest improvements we’ve seen is increased customer satisfaction,” Hynek notes. “When I present our FMEAs in the standardized AVIX format, customers appreciate the consistency and professionalism.”

The Results

The adoption of AVIX FMEA has led to several significant improvements for SSI Technologies:

✅ Improved Risk Identification – The structured framework of AVIX FMEA has enhanced the ability to proactively detect and address potential failures.

✅ Standardized Approach –  Using templates in AVIX minimizes the risk of manual errors, improving documentation quality.

✅ Increased customer satisfaction – Clients appreciate the clear and consistent reporting, which strengthens trust in the company’s quality management.

Hynek stresses the importance of standardization in process management. “In Excel, there was no real standardization,” he remarks. “AVIX prevents unusual or incorrect inputs, ensuring that when we enter severity, occurrence, and detection values, they conform to the guidelines. This reduces mistakes significantly.”