7FM Process Failure Mode and Effects Analysis
Training LengTh - 2 days

7FM PFMEA methods exceed SAE, VDA, and AIAG requirements.  7FM rationalizes functions, their sequence, and ensures requirements are met.  Functions are optimized.  Process function are analyzed and potential failure modes determined.  Failure modes are poor quality functions and an be detected.  Equipment controls detect failure modes and controls avoid producing a defect.  The control system can repeat the operation to produce a good quality part.  Suspected defects can be automatically segregated.  Defects that cannot be segregated can be tracked and removed at a following station/operation.  7FM’s  Cecil C. Craig award winning error proofing/mistake proofing methods are included in this training.


  • Overview of Process FMEA.
  • Requirements, the function, types of function, physics of the function, hierarchy of the function, sequence, and primary functions.  The 7FM DFMEA workbook.

Three levels of 7FM PFMEA

  • Material Process FMEA.  Using chemicals and energies to create the base material that is required to support dimensions with specific material properties (macro and micro analysis).
  • Manufacturing Process FMEA: Using refined materials, energy, tools, and movement to create components that have the design intent dimensions supported by material requirements (macro and micro analysis).
  • Assembly Process FMEA.  Using components, movement, tools, and energy to locate, position, orient, and join parts into assemblies, assemblies into systems, or systems into super-systems of vehicles, aircraft, ships, buildings, etc. (macro and micro analysis).

The Analysis

  • The process architecture: The primary failure modes and their relationship to design failure modes.  This is a highly focused functional block diagram that includes all direct items that touch or controls that which touches material or components (macro and micro).
  • The input functions, process functions, and primary output functions are defined, their requirements are documented, their specifications are documented.
  • The rational failure modes of the seven potential failure modes are determined and the process temporal fault state map.
  • The potential failure modes are assessed for potential equipment controls
  • All rational failure modes are linked with rational and directional causes of the potential failure modes and their internal and external effects are also linked to the failure modes.
  • Controls, Risks, and Improvements
  • How to prevent cause from being included into the process.  7FM error proofing
  • How to detecting the failure mode before the release of the process.  7FM mistake proofing
  • System Fault Detection and Mitigation.  7FM mistake proofing
  • Prioritizing Risks.  Severity (S), the risk of creation-criticality (SO), and the risk of escape (SOD also known as RPN: Risk Priority Number).  Criticality is most important to improving quality and lowering the cost of poor quality.
  • The preventive and reactive Process Control plan: Sources of Special Cause Variation.  Process monitoring and management, inspection, test, and control of nonconforming materials, and event-based sampling.
  • Recommended actions.  Removing Risks from process and product design.