Process Failure Modes Effects Analysis PFMEA Benefits PreventYou can effectively Prevent –rework, retest, re-inspection, poor quality, higher costs, etc. (Firefighting = Dollars Wasted)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! Preventing By Preventing errors or problems… You prevent waste, improve quality and cycle-times, and reduce costs !

Process Failure Modes Effects Analysis 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.

Process Failure Modes Effects Analysis Drive to Work Stuck in Traffic Late for Work Complete the next column in the PFMEA tool… Column 3 – Brainstorm and list all the effects of the failure mode(s )if it actually occurred. The effects of a failure, defect or error could be both the internal (e.g. at the next operation) effect and the external effect (e.g. at the customer) 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 How to perform a PFMEA