PFMEA

*Process Failure
Modes Effects Analysis
PFMEA Training Course
Level 1

Problem Reaction to Problems,

Poor Flow Customer
Identified Firefighting!
Business or
Manufacturing
Process

*The “P” in PFMEA = Potential, Process, or Product

**Level 1 is an “introductory” level course

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 Course Content

– Course Objectives
– What is a PFMEA?
– PFMEA – Important Points
– Benefits
– When should a PFMEA be completed?
– Example
– Review
– Additional Resources

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 Course Objectives

• Upon completion of this course participants

should understand:
• The importance and benefits of PFMEAs

• The basic PFMEA Structure

• The basic PFMEA Application

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 What is a PFMEA?

A *Process Failure Modes Effects Analysis is an

improvement tool used to:
• Analyze Risks of a business, service, or manufacturing process.

• Prevent potential and/or current defects, problems, or issues

• Analyze the effects, causes and controls of process or product defects

• Manage the improvements required to reduce or eliminate failures

• Improve flow, costs, and quality of a product or process.

• Prioritize improvement actions for management and costs decisions

*The “P” in PFMEA can stand for Potential, Process, or Product

*The PFMEA can be documented in a hard copy or software format
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 What is a PFMEA?

Process (or Product) Failure Modes Effects Analysis

• Example form
Process Failure Mode and Effect Analysis FMEA Number:
Page: of
Team Leader: Process Responsibility: Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility
Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date

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 Important Points

Everything we do is a Process!
▪ Whether it is work, school, play, manufacturing, designing, gardening, etc.
▪ All of our normal daily routines are processes
▪ We reduce, eliminate, and control “failures” in our daily lives in many ways…..for
example: If we wish to avoid getting “stuck in traffic”(failure mode) during morning
rush hour (cause) we may take an alternate route, this in a wayFMEA
Process Failure Mode and Effect Analysis
is “failure
Number:
prevention” Page: of
Team Leader: Process Responsibility: Prepared by:
Core
InTeam:
the PFMEA, it would look like this: The details will be explained later in the course Date (Orig.)
FMEA (Rev.)

Action Results
Potential Current Current Responsibility
Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

– At each of our workplaces, the details and complexities of the processes

require a more analytical approach to this “failure prevention” a.k.a. PFMEA
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 Important Points

A PFMEA is a “living” process analysis tool

(document) used for:
– Defining process or product problems
– Problem-solving and prevention
– Reducing, eliminating and controlling errors
– Continuous Improvement
– Enhancing efficiency (Lean) & quality (Six Sigma)
– Improving team effectiveness
– Analyzing Risks
– Prioritizing improvement activities

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 PFMEA Benefits

By Preventing errors or problems…

You prevent waste, improve quality and
cycle-times, and reduce costs !
• You can effectively Prevent
– rework, retest, re-inspection, poor quality, higher costs, etc.
• It costs companies less to prevent problems than to react to
them (Firefighting = Dollars Wasted)
• You can improve Cycle-times
– Time, Labor, and money is more effectively spent on “preventing”
rather than “reacting” to errors
• PFMEAs make teams more effective!
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 PFMEA Benefits

The benefit of using PFMEA’s is simple…

Problem Prevention
=
$$ Increased profits! $$

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 PFMEA Benefits

• World Class companies waste approximately 2-3% of their

Sales on “poor quality”
…all others greater than 4%!

• Costs of Poor Quality is estimated at 2-3 x the “tangible”

numbers ($$)… this means if an average company calculates
their COPQ at 5% of sales , it is realistically 10-15%! This is
due to all of the “un-captured” waste ($$)!

• Example: 100M$ Sales / 10% = $10 Million Dollars!

(this company spent $10M on doing things incorrectly!)

• This waste directly effects profits and job security for all!

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 PFMEA Benefits

• When we wait for errors to happen and then try to

correct them, this is known as “firefighting” and is
VERY costly!
• When we invest the time and resources to analyze
and prevent problems, this is known as Prevention,
and is Less Costly.

Problem Prevention
=
Reduced Product and $$
$$ Process Costs!
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 What does a PFMEA do for us?

– Provides important “documentation” of the process

• Allows you to meet customer requirements
• Meets “Continuous Improvement” requirements
• Meets many industry standards such as ISO9000, QS9000, AS9100
– Tells us the “effect” a failure could have on the customer
– Tells us which “failures” we should reduce, eliminate and control
• Allows the team to focus on the important few, instead of the trivial
many
– Provides a “Prioritized” list of required improvement actions
• Improves team efficiency when solving issues
• Teams are more focused on “priorities” that impact the business

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 When should it be completed?

PFMEA’s are most effective when completed:

• During the development of a new process, product,
or service
• Prior to “start-up” of a new process, product , or
service
• When evaluating new process equipment or tools
• For any business, transactional, or production
process that is being launched for use

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 Good Reactive Tool

PFMEA’s are also VERY effective if completed on current

processes or products, and should be performed
where there is:
• Poor quality and low yields
• High costs
• Low profit margins
• Excessive or expensive defects
• Processes that are “Not Lean” or that have poor
throughput and cycle-times
• Chronic Supplier problems
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 Preferred Approach

Usual Approach
Processes have numerous risks-high cost-rework-poor quality-poor cycle-times, customer
dissatisfaction, bottlenecks, etc. due to errors and other issues

Problem Reaction to Problems,

Poor Flow Customer
Identified Firefighting!
Business or
Manufacturing
Process

Preferred Approach
PFMEAs are performed TO MINIMIZE risks, rework, errors, and defects, thus improving
quality and cycle-times, resulting in lowered costs and customer satisfaction.
Continuous Improvement

Errors addressed Business or

PFMEA and prevented -
Process controls
Manufacturing Customer
Performed
in Place Process

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 How do we perform a PFMEA?

#1: Identify the process or product that requires the PFMEA

Analysis …
Recommended:
• New processes being launched
• Business, transaction, service, or manufacturing
process
• Current processes with poor yields, rework, errors,
defects, poor cycle-times, high costs, high customer
dissatisfaction, etc.

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 How do we perform a PFMEA?

#1: Identify the process or product that requires the PFMEA

Analysis …
Recommended:
• New processes being launched
• Business, transaction, service, or manufacturing
process
• Current processes with poor yields, rework, errors,
defects, poor cycle-times, high costs, high customer
dissatisfaction, etc.

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 How do we perform a PFMEA?

#2: Identify the team and a Leader/Consultant to

facilitate completion of the PFMEA…
Recommended:
• Use a Subject Matter Expert with PFMEA application
experience
• Those responsible for the process and have the authority to
make positive changes
• Those most familiar and “close” to the Business or
manufacturing process
• This may include customers, suppliers, engineers,
production personnel, etc.

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 How do we perform a PFMEA?

#3: Identify how the success of the PFMEA will be

measured
Recommended:
• Process metrics: Improved Quality Yields, Costs
Reductions, Reduced Cycle times, Improved Test Yields,
Increased Output/Demand etc.

• Reduction of RPNs (Risk Priority Number)

• RPNs are calculated in the PFMEA and provide a good measure
of the “effectiveness” of improvements to a process or product.
(this will be explained later in the course).

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 How to perform a PFMEA

#4: Begin the Analysis with a PFMEA *form

Let’s
Process Failure Mode andstart with the first column in the PFMEA
Effect Analysis tool
FMEA Number:
Page: of
• Column 1 – Process Function, Process Step,Name or #
Team Leader:
Core Team:
Process Responsibility: Prepared by:
FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date

Drive to
Work

We complete the column as follows…

•In Column 1 – List the process step name and/or reference number in this
column: Example- Drive to Work
we will use a simple process like “Drive to Work” to help students understand the basics

*form – the PFMEA can be created an MS Excel spreadsheet or in a purchased Software.

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 2 – Brainstorm and list all the “potential”
Process Failure Mode and Effect Analysis
failure
FMEA Number:

Team Leader:
modes for this operation. (keep it simple and focused on things
Process Responsibility:
Page:
that
Prepared by:
couldof
Core Team: actually occur, be sure to list any “actual” failures already known) FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date

Drive to Stuck in
Work Traffic

Let’s complete the next column in the PFMEA tool…

•In Column 2 – List all of the potential (but practical) Failure Modes
(errors/defects) : Example- In this case the “Failure Mode” is
“Stuck in Traffic”, in other words, this is the problem we want to prevent
•There could be several failure modes to one process, list each one and
complete the form accordingly
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 3 – Brainstorm and list all the “effects” of the
failure
Process Failure mode(s
Mode and Effect Analysis )if it actually occurred. The “effects” ofFMEA
a failure,
Number: defect
Page: of
Team Leader: or error could be both the internalProcess
(e.g. Responsibility:
at the next operation) effect and the external effect
Prepared by:
Core Team: (e.g. at the customer) FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date

Drive to Stuck in Late for

Work Traffic Work

In Column 3 – List all of the potential (internal and external) effects of the
Failure Modes, defects or errors : Example- Customer rejects, poor fit,
rework, cycle-time increase, test failure

This “effects” list will help you determine the “Severity” ranking to be
placed in column 4
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 4 – The “Severity” ranking helps us understand how serious “effect” or the
“impact” of a failure may be if it happens. It allows us to “quantify” the effects of a failure
• The “Severity” index is multiplied with the “Occurrence” index and the “Detection” index, the
Process Failure Mode and Effect Analysis FMEA Number:
resulting sum = the Risk Priority Number or the RPN, which helps us to “prioritize” which of
Page:
Team Leader: problems should be addressed first. Process Responsibility: Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Occurrence Current Current Responsibility

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date

Drive to Stuck in Late for

7
Work Traffic Work

• In Column 4 – Using the *Severity Index define the Severity “ranking” on a

scale of 1-10 :
•Example- Place a number between 1-10 in the column, according to the
“level” of severity the team feels is appropriate for the particular failure’s
“effect” it may have on the next customer.
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 5 – The “Potential Causes or Mechanisms of Failure” of a failure
Process Failure Mode and Effect Analysis FMEA Number:
can be determined by brainstorming, using data, using cause & effect diagrams,
Page: of
Team Leader: people’s experience and knowledge of the process, and the step byPrepared
Process Responsibility: step by: process
Core Team: FMEA Date (Orig.) (Rev.)
of *Root Cause Analysis
Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

• In Column 5 – : List the applicable “Causes” for the particular Failure.

•Example- In the example, we would list that “Rush Hour” would be the cause that
would create the condition where we would experience the “Failure” or getting
“stuck in traffic”. There can be more than one cause for a failure/error, it is important
to perform effective root cause analysis to ensure each cause is properly
addressed.

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 6 – The “Occurrence” ranking helps us understand
Process Failure Mode and Effect Analysis and
FMEA Number:

Team Leader:
quantify how often the failure is occurring or could occur. Prepared
Process Responsibility:
Page:
by:
of

Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

• In Column 4 – Using the *Occurrence Index define the Occurrence “ranking”

on a scale of 1-10 : Example- Place a number between 1-10 in the column,
according to the estimated times the failure mode might occur, or has occurred.
• For example: 1=1 out of 1000, 2=2 out of 400, … 10 =1 out of 2 etc.

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 7 – The “Current Process Controls-Prevention” would be any form
of “Preventive Measures” that are currently in place to “Prevent” FMEA
Process Failure Mode and Effect Analysis
the failure
Number:
Page: of
Team Leader: mode. E.g. procedures, mistake-proofing,
Process Responsibility: alarms, gages, tooling, etc.
Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 7 – : List the applicable “Causes” for the particular Failure. Example- In
the example, we would list “None”, since there are no current controls in-place to
prevent the failure mode. This also helps illustrate the “need” for prevention
controls.

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 8 – The “Current Process Controls-Detection” would be any
form of “Detection Measures” that are currently in place to “Detect” or
identify
Process Failure theAnalysis
Mode and Effect failure mode once it has occurred, this prevents the
FMEA failure
Number:
Page: of
Team Leader:
from being passed on or escaping to the customer.
Process Responsibility: Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Occurrence Current Current Responsibility

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 8 – : List the applicable “Detections” for the particular Failure. Example-
In the example, we would list “Visual” or “Inspection”, since the failure mode is
identified by a visual inspection.

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 9 – The “Detection” ranking helps us understand the
“strength” of our “detection ability” to capture the failure ifFMEA
Process Failure Mode and Effect Analysis
it happens.
Number:
Page: of
Team Leader: Process Responsibility: Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility
Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 9 – Using the *Detection Index define the Detection “ranking” on
a scale of 1-10 :
•Example- Place a number between 1-10 in the column, according to the
“level” of detection the team feels is appropriate to “identify” or “to catch” the
failure if it occurred. The higher the number, the “weaker” the detection
capability.
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 10 – The “RPN” , or Risk Priority Number ranking, helps us
understand the “priority” of a particular failure based on it’s effect,
number of occurrences, and strength of detection capability.
• The “Severity” index is multiplied with the “Occurrence” index and the
Process Failure“Detection” index, the resulting sum = the Risk Priority Number
Mode and Effect Analysis FMEA Number:or the
Page: of
Team Leader: RPN, which helps us to “prioritize” which problems shouldPrepared
Process Responsibility: be by:
Core Team: FMEA Date (Orig.) (Rev.)
addressed first.
Action Results
Potential Current Current Responsibility
Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 9 – You get the RPN number by multiplying the S x O x D=RPN :
Example- 7 x 6 x 7 = 294

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 11 – The “Recommended (Improvement) Actions) are defined.
Process FailureThese
Mode andwould be the corrective or improvement actions required to
Effect Analysis either
FMEA Number:improve

Team Leader:
the “prevention” controls, improve the “detection” controls, or to eliminate,
Process Responsibility:
Page:
Prepared by:
of

Core Team: reduce, or mitigate the failure mode. FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 11 – : List the applicable “Recommended Actions” to improve prevention,or to

improve detection for, or to eliminate the particular Failure. Example- In the example, we
would list
•“Listen to Traffic Radio” in the morning - This would be a “detection” measure to avoid
the failure mode.
•“Define Alternate Routes” – This would be a “preventive” measure to avoid the failure
mode
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 12 – The assigned person or team responsible for
Process Failure Mode and Effect Analysis
implementing and completing the “Recommended Actions” andPage:
FMEA Number:
of
Team Leader:
Core Team:
Completion Due date. Process Responsibility: Prepared by:
FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 11 – : List the assigned person or persons responsible for completing
the “Recommended Actions” to improve prevention,or to improve detection for, or to
eliminate the particular Failure. Example- In the example, Karen Smith 5-15-2000

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 How to perform a PFMEA

Complete the next column in the PFMEA

• Column 13 – The “ (Improvement) Actions Taken” are defined. These would be the
Process Failure Mode and Effect
corrective Analysis
or improvement actions completed as recommended from Column FMEA11,Number:
or above
Page: of
Team Leader: and beyond those recommendedProcess to either improve the “prevention” controls,Prepared
Responsibility: improve by: the
Core Team: “detection” controls, or to eliminate, reduce, or mitigate the failure mode.FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 6 2 84
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

•In Column 13 – : List the “Actions Taken” to improve prevention,or to improve

detection for, or to eliminate the particular Failure. Example- In the example, we
would list
•“Preset Traffic stations”-This would be an action to improve “detection” capability
•“Highlight Map” – with alternate routes, This would be an action to improve
“prevention”, to avoid the failure mode
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 How to perform a PFMEA

Complete the next column in the PFMEA

• Columns 14-17 –
Process Failure Mode and Effect Analysis After the Improvement Actions are completed,FMEA Number:
Page: of
Team Leader: recalculate the “RPN” . Process Responsibility: Prepared by:
Core Team: FMEA Date (Orig.) (Rev.)

Action Results
Potential Current Current Responsibility

Occurrence

Occurrence
Process Potential Potential

Detection
Cause(s)/ Process Process Recommended & Target

Detection
Function
Severity

Severity
Failure Effect(s) of Actions
[Process Mechanism(s) Controls Controls Action(s) Completion
Class

Mode Failure Taken

RPN

RPN
Step Name] of Failure Prevention Detection Date
Listen to Traffic Preset Traffic
Karen Smith
Drive to Stuck in Late for Rush Radio Station (Det)
7 3 2 42
7 6 None Visual 7 294 Define Alternate 5-15-2000 Highlighted
Work Traffic Work Hour Routes Map (Prev)

• The RPN number is recalculated by multiplying the “new” occurrence ranking with
the new detection ranking and the Severity ranking (which did not change thru the
improvement actions), : Example- 7 x 3 x 2 = 42
•Congratulations! You “Lowered” the risks of the failure mode thru the improvement
actions, and reduced the RPN. This gives evidence of the improvement and its
effectiveness. Now the team would move on to the next “highest” RPN.

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 PFMEA Guidelines

• One Failure Mode may have more than one root

cause!
• Keep “brainstorming” activities realistic!
• Focus on solving the highest RPNs, once the PFMEA
is complete!
• Prevention is greater investment by far than
reaction!
• PFMEA’s can help analyze and solve any
manufacturing, business, or transactional process!

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 Review

You learned:
• The basics of a PFMEA
• Why it is important to use
• How you can prevent problems, reduce
costs and improve quality
• How to complete the “basics” of a
PFMEA

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 Additional Resources

Business Performance Improvement

http://www.biz-pi.com

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