Defects, rework, inspection failures. All logged. None of it flows back.
Import or generate process flows and P&IDs from MES, ERP, Excel, or PDF. Process topologies identified automatically. AIAG step types recognized. Visual flow summary with coverage indicators per station. Click any node to see failure modes, controls, and gaps.
Process functions mapped to each station. Failure modes derived from function loss or degradation. AIAG-VDA native with AP scoring and RPN. 6M cause categories on each row: Man, Machine, Material, Method, Measurement, Environment. SC/CC/HIC classifications inherited from DFMEA carry into PFMEA rows. Each row links to the source document it came from. Evidence panel with confidence score and page reference.
Defect records, scrap logs, 8D reports, and complaints matched to PFMEA rows automatically. Failure on a verified control step is flagged as a regression. New failure patterns that don't match existing rows are suggested as additions. The engineer decides. Nothing changes without confirmation.
AIAG-format control plans generated from confirmed PFMEA rows. Each entry has station, control method, sampling frequency, and reaction plan. Cpk/Ppk targets per characteristic. Gage R&R requirements per AIAG MSA 4th Edition. Detection ratings tied to actual measurement system capability. SOPs and work instructions generated per station with phase-grouped steps, tools, safety, and acceptance criteria. Process Reliability Templates (PRTs) for systematic capacity planning and process validation. PFMEA and control plan (PPAP elements 6 and 7) produced directly.
Ask a question, get cited answers from process specs and defect records. Ask for a change, the AI proposes cell updates with reasoning. Each change has its own approve/reject button. Nothing writes without sign-off. 34 languages.
Three lanes showing how design severity flows into process controls. Click any connection to see what links them. DFMEA changes flag downstream PFMEAs and control plans. Template updates propagate to every linked PFMEA automatically.
70-90% complete. AIAG-VDA compliant with Action Priority (AP) and RPN. 6M cause analysis per row. Process steps, stations, and operation types mapped. All rows traceable to source.
AIAG-format control plans linked to PFMEA rows. Cpk/Ppk targets, Gage R&R requirements (AIAG MSA 4th Ed.), sampling frequency, and reaction plans per entry. Covers PPAP elements 6 and 7 (PFMEA and control plan).
Top process failure modes ranked by defect frequency, scrap cost, and detection difficulty. Your team knows where to focus.
Formal SOPs, procedure reference templates, and phase-grouped work instructions generated from confirmed PFMEA rows. Tools, safety, acceptance criteria on every step. Download from the sidebar.
Tasks grouped into costed programs automatically. Frequencies, pass-fail criteria, and cost estimates - all derived from the PFMEA.
Process flow diagrams and P&IDs generated from your process data. Station sequences, instrumentation, and control devices mapped. Linked to PFMEA rows and control plan entries.
Sub-tier supplier PFMEAs validated against your process. Missing coverage, inconsistent AP ratings, and unlinked controls flagged before PPAP sign-off.
Production quality data matched to PFMEA rows. Regressions flagged. Gaps surfaced as new row suggestions. Controls marked ineffective when failures recur.
Every PFMEA row scored against AIAG-VDA requirements. Generic failure modes, missing controls, and unsourced ratings flagged before your PPAP submission or IATF audit.
Pass your engineers' review → scale site-wide.
From no structured risk strategy to a fully auditable, cross-functional FMEA that feeds design changes, control plans, and process improvements.
Your engineers judge the output. 30 minutes.
