The document discusses Process Failure Modes and Effects Analysis (PFMEA) which analyzes manufacturing and assembly processes to identify potential failure modes caused by process deficiencies. A PFMEA includes a process flow diagram, failure analysis matrix, and process control plan. It assumes the design is valid, analyzes failure causes and effects, and recommends actions to eliminate root causes and detect failures. Benefits include improved processes, performance monitoring, and prioritizing resources to ensure process improvements benefit customers.

1. Process Failure Modes and Effects Analysis (PFMEA) Minimise the potential process failure and its effects on your customer Anand Subramaniam

8. PFMEA - Process Steps

9. PFMEA - Matrix Process steps / operation # from Process Flow Potential - Significant & Critical Characteristics from DFMEA High / Medium Interactions are causes / failure modes in PFMEA Characteristics Ranked in order of Importance Prioritised ranking of process steps relative to risk Severity Process Primary Process Steps Customer Assessment Direction of Improvement Potential Critical and Significant Weighted Importance Relative Importance M F H F H F M M G H M H H F H H F F M H H H H H G G M 5 3 9 3 9 9 5 0 81 81 72 0 9 41 0 0 27 54 261 3 0 54 81 3 0 0 0 27 0 45 9 9 0 0 0 0 0 0 0 Special Characteristics Matrix

12. PFMEA – Interface Process Interface Quality Audits Re-work Processes Part Buffers Product / Tooling Changeovers Alternative Processes Part Identity / Labeling Scrap Part Movement Gauging Stations Reject Handling

15. PFMEA – Benefits PFMEA Benefits Improves processes before failure occur Tracks and documents completion of projects Improves performance monitoring, fault-sensing equipment and / or test points Effective preventive maintenance plans based on the significance of failure effects Creates robust designs that consider less than ideal operating environments and poor customer habits Prioritises resources to ensure process improvement efforts are beneficial to customers Decreases warranty costs, waste, non-value added tasks Increases safety and enhances customer satisfaction