PFMEA Training Program

Master the natural flow of information that delivers Reliable Processes and Products.

Just imagine a company whose manufacturing and assembly processes are free of fire drills and focused on continuous improvement.  A company that makes process decisions based on meeting engineering requirements and customer expectations. A company that can speak with confidence, and prove with data, the manufacturing processes are in control.  A company that is sought after based on their dominance in quality control.

Process Failure Modes and Effects Analysis (PFMEA) is a methodology that is intended to identify risk within a process and define controls and actions to mitigate the risk.  It centers on a natural flow of information from the product design to the quality core tools of the manufacturing process.  The foundation of the process information starts with the process flow diagram (PFD) which feeds both the PFMEA and the Process Control Plan.  A focused 5 step approach develops an understanding of the connection of information between each of the processes that will eliminate waste, improved process efficiency and delivery of a quality product.

Learn how to compete the quality core tools of PFD, PFMEA and PCP and the natural flow of information between each process.

APQP (Advanced Product Quality Planning) Process is a structured method that defines and establishes steps necessary to ensure products meet requirements and customer expectations. PFMEA is one of the required deliverables within the APQP process. APQP also requires companies to complete process flow (PFD – Process Flow Diagram) and control plans (PCP – Process Control Plan) within the APQP deliverables. There is a linkage of information between PFD, PFMEA and PCP and this training includes an overview of each process and the connection between all three. Therefore, you are getting bonus training of how to complete PFD and PCP processes.

This training program is intended to provide an introduction and foundation of Process Flow Diagram, Process Failure Modes and Effects Analysis and Process Control Plan for anyone who is interested in implementing part or all of the methodology. The course comprehends the industry best practices and organizes them into a disciplined and logical 5 Step PFMEA Process – PLUS bonus examples of PFD, PFMEA, and PCP recommended documentation are provided!

This course is intended to provide training of process knowledge and techniques. At the end of this course you should be able to:

  • List the 5 steps in the PFMEA process (ReliaTrain PFMEA Process Map)
  • Implement Process Flow Diagrams (PFD) in a manufacturing process
  • Uncover “hidden factories” and material handling in PFDs
  • Describe the difference between value added and non-value added operation steps in PFD
  • Use information from PFD to create PFMEA
  • Use PFMEA as a tool to identify and mitigate risk in the manufacturing process
  • Use PFMEA to determine the need for error proofing within the manufacturing process
  • Use PFMEA to determine the need to consider design improvements to resolve potential quality issues
  • Use PFMEA to determine the need for preventive maintenance on tooling and fixtures
  • Use information from PFD & PFMEA to create Process Control Plans (PCP)
  • Use PFMEA and PCP to define quality checks within the manufacturing process
  • Use PFMEA and PCP to address special characteristics
  • Compare and contrast PFD, PFMEA, & PCP
  • Describe the relationship of product and process characteristics within PFMEA and PCP
  • Describe the relationship and interplay between DFMEA and PFMEA
  • Use PFMEAs to resolve the daily activity issues within manufacturing and assembly
  • Define the linkage between PFD, PFMEA and PCP
  • Uncover operations within the manufacturing process that could contribute to product issues (warranty, scrap, customer dissatisfaction, etc.)


This is a foundation training module and does not have required prerequisite training or experience.

Who Should Attend?

This course is designed to support the roles of management, design engineers, manufacturing engineers, supplier quality, validation, materials and aftermarket engineering.  If you are affected by an engineering technical decision, this course is for you.  Mastering the course content will improve launch effectiveness and product quality and reliability.