Automotive FMEA Generator

Tier: Team | Type: Tool | Category: Automotive | Version: 1.0.0

AI-assisted FMEA generation using the AIAG-VDA 7-step methodology for automotive components. Generates failure mode worksheets with severity/occurrence/detection rating estimation and built-in failure mode libraries.

1. Overview

Plugin Name: Automotive FMEA Generator Slug: automotive-fmea Required Tier: Team Plugin Type: Tool (REST API with instruction skill) Category: Automotive Author: Dryade License: DSUL

What It Does

Generates comprehensive Failure Mode and Effects Analysis (FMEA) worksheets for automotive components using the harmonized AIAG-VDA methodology. Includes a failure mode library covering electronic, mechanical, and software categories, plus structured rating scale references for consistent S/O/D evaluation.

Key Capabilities

AIAG-VDA 7-step FMEA methodology support (Design and Process FMEA)
Built-in failure mode library (30+ modes across electronic, mechanical, software)
Severity/Occurrence/Detection rating estimation with reference scales
Action Priority (AP) classification per AIAG-VDA standard

2. User Stories

Primary User Stories

US-1: Generate Draft FMEA for New Component

As a reliability engineer, I want to generate a draft FMEA worksheet from a component description and function list so that I can start with a structured baseline instead of a blank sheet.

Acceptance Criteria:

[ ] FMEA covers all listed functions
[ ] Failure modes drawn from relevant library categories
[ ] S/O/D ratings justified against rating scales
[ ] Action Priority assigned per AIAG-VDA

US-2: Look Up Failure Modes by Category

As a design engineer, I want to search the failure mode library by category and keyword so that I can ensure completeness in my FMEA.

Acceptance Criteria:

[ ] Returns failure modes matching category and keyword
[ ] Includes typical S/O/D values for reference

Edge Cases

Unknown component type: Falls back to generic failure modes and requests more context
Empty function list: Returns error prompting user to provide at least one function

3. Architecture

Component Diagram

+------------------+     +------------------+     +------------------+
|   Plugin Router  | --> |  Prompt Builder  | --> |  Data Provider   |
|  /automotive-fmea|     |  routes.py       |     |  data/*.json     |
+------------------+     +------------------+     +------------------+
                                |
                          +-----v------+
                          |  Demo Data |
                          |  FMEA libs |
                          +------------+

Dependencies

Internal: core.plugins.PluginProtocol
External: None (zero external dependencies)
Plugin: None

4. API Spec / Agent Capabilities

REST Endpoints

| Method | Path | Description | Auth | |--------|------|-------------|------| | POST | /automotive-fmea/generate | Generate FMEA worksheet | Yes | | POST | /automotive-fmea/lookup-failure-modes | Search failure mode library | Yes | | POST | /automotive-fmea/estimate-ratings | Estimate S/O/D ratings | Yes | | GET | /automotive-fmea/methodology | Get AIAG-VDA methodology reference | Yes | | GET | /automotive-fmea/status | Health check | No |

5. Data Flow

Processing Pipeline

User request arrives at plugin router
Request parameters validated via Pydantic models
Demo data loaded from data/ directory (failure modes, rating scales, methodology)
Structured prompt generated combining user input with reference data
Response returned with prompt for orchestrator processing

Demo Data Description

The data/ directory contains:

aiag_vda_methodology.json: 7-step methodology reference
rating_scales.json: S/O/D rating scales (1-10 each)
failure_mode_library.json: 30 failure modes across 3 categories
sample_fmea_acc_ecu.json: Complete FMEA example (ACC ECU)
sample_fmea_motor_controller.json: Complete FMEA example (motor inverter)
component_acc_ecu.json: Component description with functions
component_motor_controller.json: Component description with functions
fmea_worksheet_template.json: FMEA column definitions

6. Security Considerations

Data Handling

PII: No - FMEA data is engineering-only
Encryption: Standard Dryade transport encryption
Data Retention: Plugin stores no data; all processing is stateless

Isolation

Plugin runs in sandboxed context via core plugin loader
No direct database access
No external API calls in mock mode

7. Test Plan

Test Classes

| Class | Tests | Coverage Target | |-------|-------|----------------| | TestPluginAttributes | Manifest consistency | 100% manifest fields | | TestPluginRouter | Module importability | Routes and plugin | | TestPluginConfig | Data loading | All reference data files | | TestDemoData | Data presence, loadability | All data files |

Running Tests

cd dryade-plugins
python -m pytest team/automotive_fmea/tests/ -x -v --tb=short

8. Deployment Notes

Requirements

No additional Python packages required.

Configuration

Default plugin configuration:

{
    "data_source": "mock"
}

Compatibility

Min Dryade Version: 1.0.0
Python: >=3.11

9. User Guide

Getting Started

Ensure your Dryade instance has a Team tier license or higher
Install the plugin via the marketplace or dryade-pm push
Navigate to Plugins > Automotive FMEA in the workbench
Start by providing a component name, description, and function list

Common Workflows

Workflow 1: Generate FMEA for New Component

POST to /automotive-fmea/generate with component details
Review generated FMEA worksheet
Adjust S/O/D ratings based on domain expertise

Workflow 2: Research Failure Modes

POST to /automotive-fmea/lookup-failure-modes with category
Review matching failure modes and typical ratings
Add relevant modes to your FMEA

10. Screenshots

Screenshots pending marketplace submission.

11. Changelog

1.0.0 (2026-03-05)

Initial release
AIAG-VDA 7-step methodology support
Failure mode library (electronic, mechanical, software)
S/O/D rating estimation
Design and Process FMEA generation
2 sample component FMEAs (ACC ECU, motor controller)

Future Roadmap

[ ] Import existing FMEA for gap analysis
[ ] Export to Excel FMEA format
[ ] FMEA reuse across similar components
[ ] Integration with ISO 26262 safety assistant plugin

Automotive Fmea

Description

Screenshots

Details