PFMEA 4th Edition (AIAG Standard) - phanex QMS Enterprise

Active Enterprise PFMEA Projects (4th Edition)

FMEA ID	Part Number	Process Name	Rev. Level	Last Update	Status	Action

Tip: You can Double-Click on any input or text area in the table to open a larger editor popup.

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Item / Process Name

Part Number

FMEA Number

Model Year(s) / Program(s)

Core Team

Prepared By

Process Responsibility

FMEA Date (Orig)

FMEA Date (Rev)

Process Step / Function	Requirement	Potential Failure Mode	Potential Effect(s) of Failure	S	Class	Potential Cause(s) / Mechanism(s) of Failure	O	Current Process Controls Prevention	Current Process Controls Detection	D	RPN	Recommended Action(s)	Responsibility & Target Completion Date	Action Results: Actions Taken / Date	S	O	D	RPN

Control Plan (Auto-Generated from FMEA)

Data is pulled from the PFMEA Process Step, Requirement, Class, and Controls. You can manually adjust the Sample Size, Freq, and Reaction Plan here.

Process Name / Operation Description	Characteristics		Special Char. Class	Methods			Reaction Plan
Process Name / Operation Description	Product	Process	Special Char. Class	Evaluation / Measurement Technique	Sample Size & Freq.	Control Method	Reaction Plan
Click "Generate / Update Control Plan" to pull data from FMEA.

Revision History (Log Change)

Rev.	Date	Changed By	Description of Change (Reason)	Approved By
02	2026-02-22	Sombat (Process Eng.)	Updated OP 10 based on customer complaint (undersize issue). Added auto OD check and part-seated sensor to prevent misloads.	Wichai (QMR)
01	2026-01-20	Sombat (Process Eng.)	Initial Release for New Model 2026 Platform. CFT team sign-off complete.	Wichai (QMR)

FMEA Review Checklist

Mark items as checked once the review is completed.

Review Progress 0%

Effect	Criteria: Severity of Effect	Rank
Hazardous w/o warning	May endanger machine or assembly operator. Failure occurs without warning.	10
Hazardous with warning	May endanger machine or assembly operator. Failure occurs with warning.	9
Very High	100% of product may have to be scrapped. Line stop or stop ship.	8
High	Product may have to be sorted and a portion (less than 100%) scrapped.	7
Moderate	A portion (less than 100%) of the product may have to be reworked off-line.	6
Low	100% of product may have to be reworked in-station.	5
Very Low	A portion (less than 100%) of the product may have to be reworked in-station.	4
Minor	Minor inconvenience to operation, or operator.	3
Very Minor	Very minor disruption. Defect noticed by discriminating customers.	2
None	No discernible effect.	1

Effect

Criteria: Severity of Effect

Rank

Hazardous w/o warning

May endanger machine or assembly operator. Failure occurs without warning.

Hazardous with warning

May endanger machine or assembly operator. Failure occurs with warning.

Very High

100% of product may have to be scrapped. Line stop or stop ship.

High

Product may have to be sorted and a portion (less than 100%) scrapped.

Moderate

A portion (less than 100%) of the product may have to be reworked off-line.

Low

100% of product may have to be reworked in-station.

Very Low

A portion (less than 100%) of the product may have to be reworked in-station.

Minor

Minor inconvenience to operation, or operator.

Very Minor

Very minor disruption. Defect noticed by discriminating customers.

None

No discernible effect.

Probability of Failure	Possible Failure Rates	Rank
Very High: Persistent Failures	≥ 100 per thousand	10
50 per thousand	9
High: Frequent Failures	20 per thousand	8
10 per thousand	7
Moderate: Occasional Failures	5 per thousand	6
2 per thousand	5
1 per thousand	4
Low: Relatively Few Failures	0.5 per thousand	3
0.1 per thousand	2
Remote: Failure is Unlikely	≤ 0.01 per thousand	1

Probability of Failure

Possible Failure Rates

Rank

Very High: Persistent Failures

≥ 100 per thousand

50 per thousand

High: Frequent Failures

20 per thousand

10 per thousand

Moderate: Occasional Failures

5 per thousand

2 per thousand

1 per thousand

Low: Relatively Few Failures

0.5 per thousand

0.1 per thousand

Remote: Failure is Unlikely

≤ 0.01 per thousand

Detection	Criteria	Rank
Almost Impossible	Absolute certainty of non-detection. Cannot detect or is not checked.	10
Very Remote	Control is achieved with indirect or random checks only.	9
Remote	Control is achieved with visual inspection only.	8
Very Low	Control is achieved with double visual inspection only.	7
Low	Control is achieved with charting methods, such as SPC (variable).	6
Moderate	Control is based on variables gauging after parts have left the station.	5
Moderately High	Error detection in subsequent operations, OR measuring setup and first-piece check.	4
High	Error detection in-station, or error detection in subsequent ops by multiple layers of acceptance.	3
Very High	Error detection in-station (automatic gauging with automatic stop feature). Cannot pass defective part.	2
Almost Certain	Error prevention as a result of fixture design, machine design or part design. Discrepant parts cannot be made.	1

Detection

Criteria

Rank

Almost Impossible

Absolute certainty of non-detection. Cannot detect or is not checked.

Very Remote

Control is achieved with indirect or random checks only.

Remote

Control is achieved with visual inspection only.

Very Low

Control is achieved with double visual inspection only.

Low

Control is achieved with charting methods, such as SPC (variable).

Moderate

Control is based on variables gauging after parts have left the station.

Moderately High

Error detection in subsequent operations, OR measuring setup and first-piece check.

High

Error detection in-station, or error detection in subsequent ops by multiple layers of acceptance.

Very High

Error detection in-station (automatic gauging with automatic stop feature). Cannot pass defective part.

Almost Certain

Error prevention as a result of fixture design, machine design or part design. Discrepant parts cannot be made.

PFMEA (AIAG 4th Edition)

Active Enterprise PFMEA Projects (4th Edition)

POTENTIAL FAILURE MODE AND EFFECTS ANALYSIS (PROCESS FMEA)

Control Plan (Auto-Generated from FMEA)

Revision History (Log Change)

FMEA Review Checklist

SC Symbol Management

Available Classes

Linked Documents Setup

Currently Linked Documents

AIAG 4th Edition FMEA Reference Guidelines

Severity Evaluation Criteria (4th Ed)

Occurrence Evaluation Criteria (4th Ed)

Detection Evaluation Criteria (4th Ed)