Process FMEA (PFMEA)

When to Activate This Skill

• "Create a PFMEA for [process]"
• "What are the failure modes for [operation]?"
• "Calculate RPN for [risk scenario]"
• "Rate severity/occurrence/detection for [failure]"
• "Identify process risks"
• "FMEA analysis for [part/process]"

CRITICAL: Always Generate Content Directly

Every response to a PFMEA request MUST contain the actual PFMEA analysis inline — failure modes, S/O/D ratings, RPN/AP, controls, and actions written out in full. Never respond with only a plan, a reference to loading files, or an empty/deferred answer. Supplementary file reads (CLAUDE.md, templates, reference docs) are OPTIONAL background lookups — they must never replace or delay producing the actual PFMEA content in this response.

AIAG-VDA 7-Step Methodology

Step 1: Planning and Preparation

• Define scope and boundaries
• Identify team members (cross-functional)
• Gather documentation (process flow, control plan, drawings)
• Review lessons learned from similar processes

Step 2: Structure Analysis

• Define process steps from process flow diagram
• Create process tree (System > Sub-system > Process Element)
• Identify interfaces between steps
• Link to product characteristics

Step 3: Function Analysis

• Define function of each process step
• Identify product/process requirements
• Link to customer/engineering specifications
• Document special characteristics (CC/SC)

Step 4: Failure Analysis

• Identify failure modes (how can step fail to perform function?)
• Determine failure effects (consequences to customer/next operation)
• Identify failure causes (why would failure mode occur?)
• Chain: Cause → Failure Mode → Effect

Step 5: Risk Analysis

• Rate Severity (S) of effects: 1-10
• Rate Occurrence (O) of causes: 1-10
• Rate Detection (D) of controls: 1-10
• Calculate Action Priority (AP) or RPN

Step 6: Optimization

• Prioritize high-risk items
• Develop countermeasures (hierarchy: Eliminate > Substitute > Engineer > Admin > Detect)
• Assign responsibility and target dates
• Re-rate after countermeasures

Step 7: Results Documentation

• Document all analysis
• Track countermeasure completion
• Update Control Plan linkage
• Archive for lessons learned

Rating Scales (MNMUK Standard)

Severity (S) - Effect on Customer/Process

Occurrence (O) - Likelihood of Cause

Detection (D) - Ability to Detect Before Customer

Action Priority (AIAG-VDA Approach)

Instead of or in addition to RPN, use Action Priority:

RPN Thresholds (MNMUK Standard)

Note: Any Severity ≥8 requires action regardless of RPN.

Countermeasure Hierarchy

When addressing failure modes, apply controls in this priority order:

1. Eliminate - Design out the failure mode entirely
2. Substitute - Replace with less hazardous process/material
3. Engineer - Install physical safeguards, poka-yoke
4. Admin - Procedures, training, work instructions
5. Detect - Inspection, testing, monitoring

Special Characteristics

Critical Characteristics (CC)

• Safety or regulatory impact
• Marked with shield symbol or (CC)
• Requires enhanced controls
• Mandatory documentation

Significant Characteristics (SC)

• Fit, function, or durability impact
• Marked with diamond or (SC)
• Requires appropriate controls
• SPC typically required

Output Format Requirements

CRITICAL: Every PFMEA response MUST be complete. Never truncate or cut off mid-entry. Every failure mode listed MUST have:

• All causes fully documented
• S/O/D ratings for EVERY cause row
• RPN calculated for EVERY row
• Current controls listed
• Recommended actions specified
• After-action ratings included

If the full PFMEA would be very long, reduce the NUMBER of failure modes covered, but each one included MUST be 100% complete. Do not start a failure mode entry you cannot finish.

Output Format

When generating PFMEA content:

# PFMEA: [Part/Process Name]
**Part Number**: [P/N]
**Process**: [Description]
**FMEA Number**: PFMEA-[DEPT]-[SEQ]
**Revision**: [Rev] | **Date**: [YYYY-MM-DD]
**Team**: [Names/Roles]

## Process Step: [Step Name]

### Failure Mode 1: [Description]
**Function**: [What the step should do]
**Effect**: [What happens if it fails]
**Cause**: [Why it would fail]

| S | O | D | RPN | AP |
|---|---|---|-----|-----|
| X | X | X | XXX | H/M/L |

**Current Controls**:
- Prevention: [Current prevention measures]
- Detection: [Current detection measures]

**Recommended Actions**:
- [ ] [Action description] - Owner: [Name] - Due: [Date]

**After Action**:
| S | O | D | RPN | AP |
|---|---|---|-----|-----|
| X | X | X | XXX | H/M/L |

Department-Specific Guidance

Machine Shop

• Common failure modes: Dimensional OOS, surface finish, tool wear
• Focus on: Fixturing, program parameters, tool life management
• Key controls: First piece inspection, SPC, gage R&R

Damper Assembly

• Common failure modes: Leak, incorrect torque, missing component
• Focus on: Seal integrity, fastener torque, component presence
• Key controls: Leak test, torque verification, poka-yoke

LVA (Low Volume Assembly)

• Common failure modes: Wrong component, incorrect orientation, damage
• Focus on: Part identification, assembly sequence, handling
• Key controls: Visual verification, traveler documentation

FML (Final Manufacturing Line)

• Common failure modes: Test failure, labeling error, packaging damage
• Focus on: Final test parameters, traceability, packaging
• Key controls: Automated test, barcode verification, packaging audit

Integration with Related Skills

ControlPlan

PFMEA feeds directly into Control Plan:

• High S/O items require enhanced inspection
• Detection controls become Control Plan methods
• Special characteristics flow to Control Plan

Load: read ~/.claude/skills/Controlplan/SKILL.md

AutomotiveManufacturing

Work instructions should reflect PFMEA findings:

• High-risk steps highlighted
• Operator controls documented
• Quality checkpoints specified

Load: read ~/.claude/skills/Automotivemanufacturing/SKILL.md

A3criticalthinking

When PFMEA reveals issues:

• Use 5 Whys for root cause analysis
• Fishbone diagram for cause identification
• A3 format for countermeasure planning

Load: read ~/.claude/skills/A3criticalthinking/SKILL.md

Workflow Routing

Examples

Example 1 — Full PFMEA for a machining operation

User: "Create a PFMEA for the damper rod OD turning operation on the CITIZEN Swiss lathe."

Output: AIAG-VDA 7-step PFMEA in the skill's Output Format — process step "Turn Rod OD to spec" with failure modes (oversize/undersize OD, poor surface finish, chatter marks), each with Function/Effect/Cause, S/O/D ratings, RPN, Action Priority, current prevention/detection controls, recommended actions with owner/due date, and after-action re-rating. Machine Shop department guidance applied (fixturing, tool wear, first-piece inspection per Department-Specific Guidance).

Example 2 — Rating a single failure mode

User: "Rate severity, occurrence, and detection for a missed damper gas charge — dampers ship without gas."

Output: S=8 (product inoperable) or S=9 if the application is safety-critical, per the Severity table. O rated against current process controls (e.g., O=6 for a manual charge station with no verification). D rated against current detection (e.g., D=7 if only an end-of-line function test is relied on). RPN calculated, Action Priority flagged HIGH (S≥8), and the Countermeasure Hierarchy applied to recommend an Engineer-tier fix (weight-check or pressure sensor poka-yoke) over adding another visual inspection.

Example 3 — Escalating a PFMEA finding into Control Plan and 8D

User: "Our LVA PFMEA shows wrong-component assembly at RPN 144. What next?"

Output: Flags RPN ≥120 as Critical per RPN Thresholds — immediate countermeasure required, cannot ship without action. Recommends an Eliminate/Engineer-tier fix (kitting with poka-yoke tray, component-presence sensor) over an Admin-tier fix (visual check procedure). Links the finding to the ControlPlan skill to convert the new detection control into a Control Plan line, and to A3criticalthinking for 5-Whys root cause analysis if the wrong-component issue has already occurred in production.

Supplementary Resources

For detailed guidance: read ~/.claude/skills/Pfmea/CLAUDE.md

For templates: ls ~/.claude/skills/Pfmea/templates/

For rating scales: read ~/.claude/skills/Pfmea/reference/rating-scales.md

For common failure modes: read ~/.claude/skills/Pfmea/reference/common-failure-modes.md