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pfmea-process

Build a PFMEA worksheet, process risk analysis, or AP table using the AIAG-VDA FMEA Handbook 2019 7-step approach. Covers Structure Analysis, Function Analysis, Failure Analysis, Risk Analysis (Action Priority H/M/L), Optimization, and Documentation. Required by IATF 16949 and OEM customer-specific requirements for new processes, process changes, and post-escape PFMEA updates.

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# Process FMEA (PFMEA) — AIAG-VDA 2019

## Goal

Identify and prioritise process risk before production — using the AIAG-VDA 2019 7-step approach — so that high-priority failure modes are eliminated or controlled before they reach the customer, and the result feeds directly into the Control Plan and Work Instructions.

## Required Execution Checklist

- [ ] Scope defined: process step boundaries, model year, team assembled with cross-functional representation
- [ ] Process Flow Diagram (PFD) available and used as Step 2 input
- [ ] All process steps in the PFD have a corresponding entry in Structure Analysis (Step 2)
- [ ] Every process step has at least one Function defined in Step 3
- [ ] Failure chain complete for each function: Effect → Mode → Cause (in this direction — not reversed)
- [ ] All Failure Causes are evidence-based — no unverified assumptions used as final causes