# Build a process FMEA for a new or changed production step

A process FMEA table with failure modes, effects, causes, current controls, and severity/occurrence/detection ratings, plus prioritized actions.

- Topic: Projects & Operations
- Framework: RTF
- Level: Advanced
- Tags: Analyze, Fill-in Template
- Source: https://www.thinkwithprompt.com/prompts/build-a-process-fmea-for-a-new-or-changed-production-step

## Prompt

```text
Help me build a process FMEA (PFMEA) for a production step.

**Process step(s):** [e.g. "Op 30: press-fit bearing into housing"]
**What changed or why now:** [new line / new part / process change / customer complaint / annual review]
**Product requirements this step must deliver:** [special or critical characteristics, tolerances, torque, dimensions]
**Equipment and controls in place today:** [machines, fixtures, poka-yokes, gauges, inspection frequency]
**Known history:** [past defects, scrap reasons, complaints, or "none"]
**Rating scale we use:** [AIAG-VDA 2019 with Action Priority / classic RPN / our own 1-10 tables]

Work through the step like a cross-functional team would:
1. Break the step into its process functions and requirements.
2. For each, list realistic failure modes (what goes wrong at this step), the effect on the next operation, the end customer, and safety or regulatory compliance, and the causes at the 4M level (man, machine, method, material) plus environment and measurement.
3. List current prevention controls and detection controls separately. Do not count an operator visual check as strong detection.
4. Suggest severity, occurrence, and detection ratings with a one-line reason each, and mark every rating [TEAM TO CONFIRM].
5. Rank by Action Priority (High/Medium/Low) or RPN, whichever scale I named.

Return:
- A table: Function/requirement | Failure mode | Effect | S | Cause | Prevention control | O | Detection control | D | AP or RPN | Recommended action | Owner | Due date.
- The top 5 risks with an action that lowers occurrence or improves detection, preferring error-proofing over added inspection.
- Questions the team must answer on the floor before finalizing.

Do not invent defect rates or history. A PFMEA is a team document: treat this as a first draft for the team review, not a finished analysis.
```

## What to fill in

- e.g. "Op 30: press-fit bearing into housing"
- machines, fixtures, poka-yokes, gauges, inspection frequency
- past defects, scrap reasons, complaints, or "none"
- TEAM TO CONFIRM

Free to copy and use. From ThinkWithPrompt (https://www.thinkwithprompt.com/), a library of 2,663 curated AI prompts.