PFMEA and the Control Plan - Overview and Application C1511

Topics: Quality, Safety & Maintenance

The Process FMEA and Control Plan program introduces the basic concepts behind this important tool and provides training in how to conduct an effective PFMEA. First, the course explains what a PFMEA is and how it improves the long-term performance of your products, services and related processes by addressing process related failures. The role of the PFMEA in the overall framework of Quality Management System Requirements is explained as well as the role of the PFMEA in the Advanced Product Quality Planning (APQP) process. Additionally, the differences and relationships between the DFMEA and PFMEA are well defined. With this background information, the course provides a systematic, standardized approach for completing the Process FMEA. Outputs from PFMEAs are essential inputs to Control Plans. This course pairs training on building Control Plans with PFMEAS because of this relationship. The basic format for and methodology for building, using and maintaining an effective Control Plan is presented.
Learning Objectives

By attending this seminar, participants will be able to:

  • Describe how the PFMEA can drastically improve the long-term reliability of their organization's products and processes
  • Describe the role of the PFMEA within a quality management system
  • Describe the differences and relationships between the PFMEA and DFMEA
  • Build and lead a Cross-functional Team for completing a PFMEA
  • Follow the AIAG Potential Failure Mode and Effects Analysis Reference Manual for completing a PFMEA
  • Conduct a Brainstorming Session aimed at eliminating process failures
  • Develop and use a Process Flow Diagram for use as a job aid in completing the PFMEA
  • Document of the analyses results on the standard PFMEA form
  • Use the Process Controls identified during the PFMEA as inputs to the Control
  • Create, Employ and Maintain a Control Plan

Who Should Attend

This PFMEA and the Control Plan course will provide training to a manufacturer’s process engineering, development, operations, quality and administrative personnel. These individuals are typically involved in the development and production of parts for direct use in the manufacture of automobiles or other manufactured items. Technical managers of personnel involved in the above would benefit as well.


Participants should have previous participated in Quality Planning activities and/or anticipate an upcoming assignment to participate on a PFMEA cross-functional team.

You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

I. Introductions
  • Instructor qualifications
  • Participant’s job roles and experience
  • Examples of process issues that lead to failures

II. Define Basic Reliability Concepts that Set the Stage for the Completion of the PFMEA

  • Identify reliability and basic quality concepts such as the Bathtub Curve, Failures and what it takes to consistently meet customer requirements
  • Analyze failures related to design weaknesses as opposed to failures related to process issues
  • Determine the difference between process failure modes and effects
III. Comprehend the Need for the PFMEA
  • Essential factors that play a significant role for a company to successfully provide quality products and services
  • Benefits to the organization its customers and employees
  • The role of the PFMEA in Quality Management System (QMS), Advance Product Quality Planning (APQP) and relationship to the Control Plan as well as other tools/techniques
IV. Identify the basic requirements for effective completion of the PFMEA
  • Cross functional team approach
  • Process Flow Diagram
  • Use of the AIAG form to guide the PFMEA
  • Analysis and problem solving
  • Follow-up and implementation
  • The FMEA as a “Living Document”
V. Explain the role of the Process Control Plan, describe the basic layout of an effective Process Control Plan and explain how to complete a Process Control Plan
  • Basic Entries
  • Effective Control Strategies
  • Effective Reaction Strategies
VI. Construct a Process Flow Diagram and use it to assure thorough analysis of the product process under review

VII. Begin a PFMEA and interpret the results (simulated data or real data, if onsite training)
  • Identification of potential failures
  • Prediction of failure modes and the severity of failures
  • Estimations of the probability of failure occurrence
  • Identification of associated risks and effects of failures
  • Identify, analyze and implement design controls
  • Calculation and interpretation of the Risk Priority Number (RPN)
  • Follow-up and implementation of recommendations
VIII. Employ the Results of the PFMEA to Begin a Process Control Plan
  • A basic template/format
  • Effective control strategies
  • Effective responses
  • Updates
Curtis Pawloski

Curtis PawloskiCurt Pawloski is President/Senior Consultant for Integral Operations, Inc.  Since 1995, he has been consulting and training based on his expertise  in; project management, geometric dimensioning and tolerancing (GD&T), process and quality improvement, problem solving, and quality system development and implementation. Mr. Pawloski has helped auto industry OEMs and numerous supplier organizations prepare or improve their quality systems, facilitated the writing of quality procedures and work instructions, and consulted on implementation of quality systems. His focus over the last two decades is on improving business processes and human performance through training, consulting and leveraging the use of the best tools possible. In addition, he was the leader of a team to develop a comprehensive project management training and certification system for Volkswagen's IT function. Mr. Pawloski has led hundreds of seminars and consulting sessions for the SAE covering the applications of GD&T and a wide array of Quality topics. He is also an Adjunct Faculty Member at Oakland Community College, Delta College, and Midlands Technical College.  He is a board member and past member of the year for the Saginaw Valley Section of the American Society for Quality. He has a B.S.ChE from the University of Michigan, a Graduate Certificate in Hazardous Materials Management/Chemical Engineering from Wayne State University, and an M.B.A. from Wayne State University. Certifications include American Society for Quality Certified Quality Engineer and ASME Certified Senior GD&T Professional.

Duration: 0 Day
CEUs: .7

Fees: $699.00

This seminar is available for Private Delivery Corporate Learning Engagements only. Request Information »
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