pfmea-processlisted

# 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 --- ## When to use - New process development (pre-production) - Existing process change or transfer - After a quality escape (update to reflect failure mode) - Periodic review (IATF requires annual review or at change) - Customer-specific requirement (Ford, GM, Stellantis, BMW, VW all require PFMEA) ##