FMEA-MSR: Monitoring and System Response

FMEA-MSR supplements Design and Process FMEAs for safety-relevant failure modes where prevention and detection controls at the manufacturing stage are insufficient. It analyzes how the vehicle’s onboard systems monitor for failures during operation and what system response occurs when a failure is detected.

Typical applications: ABS/ESC systems, powertrain control modules, ADAS features, battery management systems, steering assist systems — any subsystem where a failure during operation could affect vehicle safety.

For each safety-relevant failure mode from your DFMEA or PFMEA, define:

**Monitoring function**: How the vehicle detects the failure during operation (e.g., ‘ABS module monitors wheel speed sensor signal continuity’).

**System response**: What the vehicle does when monitoring detects a failure (e.g., ‘activate warning lamp, enter limp-home mode, disable cruise control’).

**Monitoring ratings**: Frequency of monitoring (FM), monitoring coverage (M), and vehicle response adequacy, scored on 1-10 scales.

Each FMEA-MSR entry traces back to the originating failure mode in the parent DFMEA or PFMEA, maintaining full risk traceability from design through manufacturing through field operation.