pfmea

name	Pfmea
description	Generate AIAG-VDA compliant Process FMEAs with proper Severity/Occurrence/Detection ratings, RPN calculations, and countermeasure recommendations. Covers MNMUK departments (Machine Shop, Damper, LVA, FML). USE WHEN user says 'PFMEA', 'FMEA', 'failure mode', 'risk analysis', 'RPN', 'severity occurrence detection', or 'process risk assessment'. Integrates with AutomotiveManufacturing, ControlPlan, and A3criticalthinking skills.
effort	high

Process FMEA (PFMEA)

When to Activate This Skill

• "Create a PFMEA for [process]"
• "What are the failure modes for [operation]?"
• "Calculate RPN for [risk scenario]"
• "Rate severity/occurrence/detection for [failure]"
• "Identify process risks"
• "FMEA analysis for [part/process]"

CRITICAL: Always Generate Content Directly

Every response to a PFMEA request MUST contain the actual PFMEA analysis inline — failure modes, S/O/D ratings, RPN/AP, controls, and actions written out in full. Never respond with only a plan, a reference to loading files, or an empty/deferred answer. Supplementary file reads (CLAUDE.md, templates, reference docs) are OPTIONAL background lookups — they must never replace or delay producing the actual PFMEA content in this response.

AIAG-VDA 7-Step Methodology

Step 1: Planning and Preparation

• Define scope and boundaries
• Identify team members (cross-functional)
• Gather documentation (process flow, control plan, drawings)
• Review lessons learned from similar processes

Step 2: Structure Analysis

• Define process steps from process flow diagram
• Create process tree (System > Sub-system > Process Element)
• Identify interfaces between steps
• Link to product characteristics

Step 3: Function Analysis

• Define function of each process step
• Identify product/process requirements
• Link to customer/engineering specifications
• Document special characteristics (CC/SC)

Step 4: Failure Analysis

• Identify failure modes (how can step fail to perform function?)
• Determine failure effects (consequences to customer/next operation)
• Identify failure causes (why would failure mode occur?)
• Chain: Cause → Failure Mode → Effect

Step 5: Risk Analysis

• Rate Severity (S) of effects: 1-10
• Rate Occurrence (O) of causes: 1-10
• Rate Detection (D) of controls: 1-10
• Calculate Action Priority (AP) or RPN

Step 6: Optimization

• Prioritize high-risk items
• Develop countermeasures (hierarchy: Eliminate > Substitute > Engineer > Admin > Detect)
• Assign responsibility and target dates
• Re-rate after countermeasures

Step 7: Results Documentation

• Document all analysis
• Track countermeasure completion
• Update Control Plan linkage
• Archive for lessons learned

Rating Scales (MNMUK Standard)

Severity (S) - Effect on Customer/Process

Rating	Criteria	MNMUK Examples
10	Affects safety without warning	Brake component failure, no containment possible
9	Affects safety with warning	Safety critical dimension OOS, detectable at assembly
8	Product inoperable, 100% scrap	Part cannot be reworked, total loss
7	Product operable but degraded, customer dissatisfied	Performance below spec, customer complaint
6	Product operable, comfort/convenience affected	Cosmetic defect, minor fit issue
5	50% of product may need rework	Significant rework required
4	Product requires sorting/rework	Sorting operation needed
3	Minor rework at station	In-station repair possible
2	Slight inconvenience	Minor adjustment
1	No effect	No discernible impact

Occurrence (O) - Likelihood of Cause

Rating	Failure Rate	Cpk Equivalent	MNMUK Examples
10	Very high: ≥100/1000	<0.33	New process, no controls
9	High: 50/1000	≥0.33	Known problem process
8	High: 20/1000	≥0.51	Similar process had failures
7	Moderately high: 10/1000	≥0.67	Occasional failures observed
6	Moderate: 2/1000	≥0.83	Infrequent failures
5	Moderately low: 0.5/1000	≥1.00	Controlled process, some failures
4	Low: 0.1/1000	≥1.17	Well-controlled process
3	Very low: 0.01/1000	≥1.33	Capable and controlled
2	Remote: 0.001/1000	≥1.50	Proven design and controls
1	Nearly impossible: ≤0.001/1000	≥1.67	Failure eliminated by design

Detection (D) - Ability to Detect Before Customer

Rating	Detection Capability	MNMUK Examples
10	No detection possible	No inspection, no opportunity to detect
9	Unlikely to detect	Random sampling only, infrequent
8	Low: Visual inspection by operator	100% visual check, variable attention
7	Very low: Double visual inspection	Two operators check
6	Low: Charting/SPC	Control charts, trend monitoring
5	Moderate: Attribute gaging	Go/No-go gaging
4	Moderately high: Variable gaging	Measurement with limit checking
3	High: Automated in-process test	Automatic measurement, alarm
2	Very high: Error-proofing	Poka-yoke prevents defect production
1	Almost certain: Error-proofing prevents cause	Design makes failure impossible

Action Priority (AIAG-VDA Approach)

Instead of or in addition to RPN, use Action Priority:

Priority	Criteria	Action Required
HIGH	S=9-10 (any O, D) OR S=7-8 with O≥4 AND D≥4	Immediate action required
MEDIUM	S=5-8 with O≥4 OR D≥4	Action recommended
LOW	All others	Monitor and document

RPN Thresholds (MNMUK Standard)

RPN Range	Priority	Required Action
≥120	Critical	Immediate countermeasure, cannot ship without action
80-119	High	Countermeasure required before PPAP
40-79	Medium	Countermeasure recommended
<40	Low	Monitor, no immediate action

Note: Any Severity ≥8 requires action regardless of RPN.

Countermeasure Hierarchy

When addressing failure modes, apply controls in this priority order:

1. Eliminate - Design out the failure mode entirely
2. Substitute - Replace with less hazardous process/material
3. Engineer - Install physical safeguards, poka-yoke
4. Admin - Procedures, training, work instructions
5. Detect - Inspection, testing, monitoring

Special Characteristics

Critical Characteristics (CC)

• Safety or regulatory impact
• Marked with shield symbol or (CC)
• Requires enhanced controls
• Mandatory documentation

Significant Characteristics (SC)

• Fit, function, or durability impact
• Marked with diamond or (SC)
• Requires appropriate controls
• SPC typically required

Output Format Requirements

CRITICAL: Every PFMEA response MUST be complete. Never truncate or cut off mid-entry. Every failure mode listed MUST have:

• All causes fully documented
• S/O/D ratings for EVERY cause row
• RPN calculated for EVERY row
• Current controls listed
• Recommended actions specified
• After-action ratings included

If the full PFMEA would be very long, reduce the NUMBER of failure modes covered, but each one included MUST be 100% complete. Do not start a failure mode entry you cannot finish.

Output Format

When generating PFMEA content:

# PFMEA: [Part/Process Name]
**Part Number**: [P/N]
**Process**: [Description]
**FMEA Number**: PFMEA-[DEPT]-[SEQ]
**Revision**: [Rev] | **Date**: [YYYY-MM-DD]
**Team**: [Names/Roles]

## Process Step: [Step Name]

### Failure Mode 1: [Description]
**Function**: [What the step should do]
**Effect**: [What happens if it fails]
**Cause**: [Why it would fail]

| S | O | D | RPN | AP |
|---|---|---|-----|-----|
| X | X | X | XXX | H/M/L |

**Current Controls**:
- Prevention: [Current prevention measures]
- Detection: [Current detection measures]

**Recommended Actions**:
- [ ] [Action description] - Owner: [Name] - Due: [Date]

**After Action**:
| S | O | D | RPN | AP |
|---|---|---|-----|-----|
| X | X | X | XXX | H/M/L |

Department-Specific Guidance

Machine Shop

• Common failure modes: Dimensional OOS, surface finish, tool wear
• Focus on: Fixturing, program parameters, tool life management
• Key controls: First piece inspection, SPC, gage R&R

Damper Assembly

• Common failure modes: Leak, incorrect torque, missing component
• Focus on: Seal integrity, fastener torque, component presence
• Key controls: Leak test, torque verification, poka-yoke

LVA (Low Volume Assembly)

• Common failure modes: Wrong component, incorrect orientation, damage
• Focus on: Part identification, assembly sequence, handling
• Key controls: Visual verification, traveler documentation

FML (Final Manufacturing Line)

• Common failure modes: Test failure, labeling error, packaging damage
• Focus on: Final test parameters, traceability, packaging
• Key controls: Automated test, barcode verification, packaging audit

Integration with Related Skills

ControlPlan

PFMEA feeds directly into Control Plan:

• High S/O items require enhanced inspection
• Detection controls become Control Plan methods
• Special characteristics flow to Control Plan

Load: read ~/.claude/skills/Controlplan/SKILL.md

AutomotiveManufacturing

Work instructions should reflect PFMEA findings:

• High-risk steps highlighted
• Operator controls documented
• Quality checkpoints specified

Load: read ~/.claude/skills/Automotivemanufacturing/SKILL.md

A3criticalthinking

When PFMEA reveals issues:

• Use 5 Whys for root cause analysis
• Fishbone diagram for cause identification
• A3 format for countermeasure planning

Load: read ~/.claude/skills/A3criticalthinking/SKILL.md

Workflow Routing

Trigger	What to do
"create a PFMEA for [process]" / "FMEA analysis for [part/process]"	Run the full AIAG-VDA 7-Step Methodology; emit the Output Format markdown with one Failure Mode block per row, S/O/D + RPN + AP for every cause, current controls, recommended actions, and after-action re-rating
"what are the failure modes for [operation]?"	Use Failure Analysis (Step 4) plus reference/common-failure-modes.md for the relevant department; chain Cause → Failure Mode → Effect for each candidate
"rate severity/occurrence/detection for [failure]" / "calculate RPN for [scenario]"	Apply the Rating Scales tables (S/O/D) and compute RPN + Action Priority per the Action Priority and RPN Thresholds tables; flag S≥8 as requiring action regardless of RPN
"identify process risks" / dept-specific PFMEA (Machine Shop, Damper, LVA, FML)	Apply the matching Department-Specific Guidance block for common failure modes, focus areas, and key controls before running Steps 1-7
"what countermeasure / how do we fix this failure mode?"	Apply the Countermeasure Hierarchy (Eliminate > Substitute > Engineer > Admin > Detect) — never default to an added inspection when a higher-tier fix is feasible
"link PFMEA to control plan" / "special characteristics"	Use Special Characteristics (CC/SC) rules, then hand off to the ControlPlan skill per Integration with Related Skills
"PFMEA calibration session" / "team composition" / "review triggers" / advanced/edge-case PFMEA questions	read ~/.claude/skills/Pfmea/CLAUDE.md for team composition, rating calibration, control effectiveness matrix, and update triggers

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Examples

Example 1 — Full PFMEA for a machining operation

User: "Create a PFMEA for the damper rod OD turning operation on the CITIZEN Swiss lathe."

Output: AIAG-VDA 7-step PFMEA in the skill's Output Format — process step "Turn Rod OD to spec" with failure modes (oversize/undersize OD, poor surface finish, chatter marks), each with Function/Effect/Cause, S/O/D ratings, RPN, Action Priority, current prevention/detection controls, recommended actions with owner/due date, and after-action re-rating. Machine Shop department guidance applied (fixturing, tool wear, first-piece inspection per Department-Specific Guidance).

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Example 2 — Rating a single failure mode

User: "Rate severity, occurrence, and detection for a missed damper gas charge — dampers ship without gas."

Output: S=8 (product inoperable) or S=9 if the application is safety-critical, per the Severity table. O rated against current process controls (e.g., O=6 for a manual charge station with no verification). D rated against current detection (e.g., D=7 if only an end-of-line function test is relied on). RPN calculated, Action Priority flagged HIGH (S≥8), and the Countermeasure Hierarchy applied to recommend an Engineer-tier fix (weight-check or pressure sensor poka-yoke) over adding another visual inspection.

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Example 3 — Escalating a PFMEA finding into Control Plan and 8D

User: "Our LVA PFMEA shows wrong-component assembly at RPN 144. What next?"

Output: Flags RPN ≥120 as Critical per RPN Thresholds — immediate countermeasure required, cannot ship without action. Recommends an Eliminate/Engineer-tier fix (kitting with poka-yoke tray, component-presence sensor) over an Admin-tier fix (visual check procedure). Links the finding to the ControlPlan skill to convert the new detection control into a Control Plan line, and to A3criticalthinking for 5-Whys root cause analysis if the wrong-component issue has already occurred in production.

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Supplementary Resources

For detailed guidance: read ~/.claude/skills/Pfmea/CLAUDE.md

For templates: ls ~/.claude/skills/Pfmea/templates/

For rating scales: read ~/.claude/skills/Pfmea/reference/rating-scales.md

For common failure modes: read ~/.claude/skills/Pfmea/reference/common-failure-modes.md