Foundations & PFMEA Development Process
Module 1:
Introduction to PFMEA
- What is FMEA and why PFMEA is
required
- Linkage with APQP, Control Plan,
and Process Flow
- Benefits, goals, and expected
outcomes
- Key terminologies (Failure Mode,
Effects, Causes, Controls, RPN, Action Priority)
Module 2:
Understanding Process Flow & Structure
- Mapping processes using Process
Flow Diagrams
- Identifying process steps,
interfaces & critical characteristics
- Alignment of PFMEA with process
steps (structure analysis)
Module 3:
Function & Requirement Analysis
- Defining functions of each process
step
- Determining functional requirements
and potential deviations
- Inputs/outputs for each function
Module 4:
Identifying Failure Modes & Effects
- Techniques for identifying failure
modes
- Assessing potential effects of
failures
- Ranking severity: guidelines &
examples (AIAG-VDA standard)
Module 5:
Identifying Causes & Prevention Controls
- Common cause categories in
manufacturing processes
- Linking causes to process inputs
- Determining existing prevention
& detection controls
Scoring, Action Priorities, and PFMEA Implementation
Module 6:
Detection Controls & Scoring Criteria
- Understanding prevention vs
detection
- Ranking occurrence & detection
- Scoring tables and industry
benchmarks (AIAG-VDA aligned)
Module 7:
Action Priority (AP) & Risk Reduction
- AP vs RPN: latest methodology
- Identifying actions for high-risk
items
- Assigning responsibilities,
timelines & tracking actions
Module 8:
Creating the PFMEA Worksheet
- Step-by-step PFMEA form preparation
- Translating process flow into PFMEA
rows
- Group exercise: Build partial PFMEA
for a sample process
Module 9:
Linking PFMEA to Control Plan
- How PFMEA drives control planning
- Identifying characteristics subject
to special controls
- Ensuring alignment between PFMEA,
Work Instructions & Control Plan
Module 10:
Review, Validation & Best Practices
- Conducting cross-functional reviews
- Common mistakes & how to avoid
them
- Maintaining PFMEA during process
changes
- PFMEA updates post customer
complaints or internal NCs
Closing
Session
- Q&A
- Summary of key concepts
- ProgNXT Assessment
- ProgNXT Certification
