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Process FMEA

Process FMEA

This 1-day course is widely applicable to companies that produce products or provide services. It is also designed to support the requirements of IATF 16949 and Six Sigma activities. The content is delivered through a series of presentation slides, combined with a variety of participant activities.

Course Details


The key objectives are to enhance the participants’ existing knowledge and skills to enable them to become more effective at managing their work process, and meeting customer requirements. The aim is that by the end of the course, a participant will understand:

  • The role of FMEA in new product / service introduction, process management and improvement
  • How to develop and interpret a PFMEA
  • How process problems and product failures can be avoided
  • How other tools and techniques complement FMEA
  • The control plan methodology
  • The link with quality management requirements, e.g. IATF 16949, APQP / PPAP



Cross-functional: Project and engineering managers, process owners & engineers, project engineers, quality engineers, sales engineers, quality auditors, and other personnel who are involved with the introduction of new products and contribute to APQP / PPAP activities. Also, those personnel who need to understand the principles and terminology in order to communicate effectively with customers and suppliers.


  • Start 09:00
  • Introductions and Review of Agenda
  • Introduction to Advanced Product Quality Planning (APQP) and FMEA
  • Overview of Design FMEA; relationship with Process FMEA
  • Developing a Process FMEA (PFMEA)
    Defining a Process
    Identifying Failure Modes, Effects and Severity
    Special Characteristics
    Causes and Occurrence
    Process Controls and Detection
    Interpretation of Ratings, Risk Prioritisation, Improvement Actions
  • Teams present their FMEA results
  • Control Plan Methodology
  • Finish 16:30 Course Review & Closing Summary