PPAP deliverable guide

How to complete Process FMEA (PFMEA)

The PFMEA identifies how a manufacturing process could fail to meet a product or process requirement and defines actions to reduce that risk.

Complete the fields

Process step and function
Use the process-flow step number and describe what the step must accomplish.
Failure mode
State how the step can fail to meet its function or requirement: omitted operation, wrong component, wrong torque, damaged feature, and similar specific failures.
Potential effects
Describe the consequence for the next operation, customer, or end user. Use the required Severity method where applicable.
Potential causes
State the process mechanism: wrong program, worn fixture, incorrect setup, mixed material, inadequate parameter, and so on. “Operator error” is not a sufficient cause.
Prevention controls
Identify controls that prevent or reduce the cause, such as error-proofing, locked program, parameter limits, fixture design, or setup verification.
Detection controls
Identify controls that detect the failure or cause, such as sensor verification, automated inspection, audit, or test.
Risk evaluation and action
Use the approved traditional Severity/Occurrence/Detection/RPN method or AIAG/VDA Action Priority method. Assign specific actions, owners, dates, and completion evidence.

Step-by-step completion sequence

  1. Freeze the process-flow revision and form a team that includes operators and process support roles.
  2. Analyze each step and interface for credible failure chains.
  3. Document existing controls accurately and prioritize action with the required method.
  4. Implement actions, verify effectiveness, and transfer production controls to the Control Plan.
  5. Review the PFMEA after process changes, escapes, audit findings, and lessons learned.
PPAP control point: The customer’s current submission request, customer-specific requirements, and approved forms control. This guide explains a practical way to prepare the record; it does not authorize a substitute format or acceptance criterion.