Using a Process Failure Mode and Effects Analysis, also referred to as Process FMEA, is one of the most common types of FMEA and is focused on assessing and improving specific processes. Like an FMEA, the results will prioritize higher risks with the goal to work on improving the process. The same three categories exist when completing a Process FMEA: severity, occurrence, and detection. Assign a score of one to ten to each category with one meaning low risk, low probability of occurring, and that failure will most likely be detected in the testing phase. A score of ten on the other hand will denote an extremely high risk, the failure is most likely to occur, and any faults of failures will not be detected.

 The resulting scores will be multiplied to determine the Risk Priority Number (RPN). This number once sorted from highest to lowest) will give you a list with the processes that need he most attention at the top. Managers will then be able to address ways to solve the potential failures through improved process controls or increased detection controls. Managers can use the PFMEA framework to analyze any processes that takes place within the scope of manufacturing. 

It is important to note these analyses should be completed by a team, identify which processes could really benefit from an FMEA, and to include workers who have extensive experience with the process at hand. Completing a PFMEA would also greatly improved by the team performing a Gemba walk focused on processes to fully understand issues that may arise.

 

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