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
• S/O/D ratings agreed by the cross-functional team and documented
• All Special Characteristics have S=9 or S=10
• Every H-AP item has a named owner, target date, and is tracked to closure
• PFMEA detection controls match the Control Plan; prevention controls match Work Instructions