Ford, Stellantis, Renault, and GM all mandate Reverse FMEA in their Customer-Specific Requirements. Most teams run R-FMEA on paper, then manually update the PFMEA in Excel or APIS IQ weeks later - if ever. Tacit AI closes the loop automatically.
Document what happened at the workstation: which error proofing held, which was bypassed, which failure modes the PFMEA never predicted. Structured capture replaces handwritten notes and spreadsheet logs.
New failure modes, causes, and controls discovered during R-FMEA flow directly into the PFMEA. Severity, occurrence, and detection scores recalculate. No manual re-entry into APIS IQ or Excel.
A gap found on one machine gets flagged across all similar equipment and production lines. One R-FMEA finding updates every affected PFMEA, not just the one you tested.
When the PFMEA changes, the control plan changes. New detection methods, updated reaction plans, revised inspection frequencies - all linked. Traceability from R-FMEA finding to control plan entry is automatic.
Full traceability from shop-floor finding to PFMEA update to control plan change. Who ran the R-FMEA, when, what was tested, what was found, what changed. Ready for IATF 16949 audits, customer process audits, and launch readiness reviews.
Plan R-FMEA events by risk priority, equipment criticality, or customer mandate. Track completion across hundreds of stations. Prioritize where the gaps are highest, not where it is most convenient.
“Organizations are required to have a process in place that ensures all new launches complete an RFMEA event once the equipment is installed and running.” Evidence of Reverse FMEA events must be available.
“There is a Reverse PFMEA (proactive approach) process in place to identify new potential failure modes or verify the existing failure modes on the shop floor.” Auditors verify deliberate defect creation at workstations.
“R-FMEA is mandatory. Organizations must use Reverse FMEA to update FMEA assessments and transition from corrective to preventive actions.”
“The organization shall incorporate tools such as reverse PFMEA or other similar methods to assist in the PFMEA review… annually at a minimum.” A proactive review approach is required.
Your PFMEA must prove it reflects shop-floor reality - not just what was written at launch. Bring one PFMEA. See the gaps. 30 minutes.
Deploying with a Fortune 50 pharma site. Contracted with a global German OEM.
