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PFMEA & Control Plan _ Heart of manufacturing industry
Rating: 3.4 out of 5(65 ratings)
165 students

PFMEA & Control Plan _ Heart of manufacturing industry

This is not theoretical training, it's more about practical examples and logics to understand step by step process.
Created byJohn 's
Last updated 11/2025
English

What you'll learn

  • Various types of FMEA's
  • Understanding Severity, Occurrence & Detection Ranking Tables and it's criteria
  • Difference between DFMEA and PFMEA
  • Common Approach which applied in both DFMEA and PFMEA
  • Definition and terms used in FMEA & it's linkage
  • Approach used to address Recommended actions based on SxO & SxD Logic
  • Recommended action with examples over Severity, Occurrence & detection
  • Output of PFMEA and Input for Control plan.
  • Detailed Explanation of Control plan & linkage with PFMEA & Drawings
  • Real-time examples on how to perform FMEA for different industries

Explore related topics

Course content

3 sections • 19 lectures • 2h 52m total length

  • Introduction2:44

    Control Plan and PFMEA aren’t just documents—they’re the backbone of consistent, defect-free automotive manufacturing.

  • Why this course is important for You?1:32

    FMEA & Control plan helps the team proactively identify how a manufacturing process can fail, understand the risk (severity, occurrence, detection), and take preventive actions before defects reach the customer. It builds a risk-based mindset and reduces rework, scrap, and warranty issues.

  • Control Plan_ Introduction2:13

    Control plan is bible of any manufacturing process. And it is very much essential to create and use in right way. You will learn key concepts that helps you apply in your work.

  • FMEA Case Study2:52

    Case study helps you to understand the FMEA concept very easily.

  • Types of FMEA with Automotive System Examples2:07

    Explore the types of FMEA used in automotive applications, including system FMEA, design FMEA, and service FMEA, to identify failures, assess risks, and implement controls across design, manufacturing, and maintenance.

  • Types of FMEAs and their Relationship2:11

    Explore the types of fmeas: system, design, process, and machine, and how each targets different scopes, from vehicle function risks to manufacturing defects, to maximize quality, reliability, cost, and maintainability.

  • Test your FMEA and Control Plan Knowledge.
  • Why FMEA?6:19

    This chapter explains you why FMEA is important for any sector or industry interests of Safe operation of products.

  • Difference Between DFMEA & PFMEA7:27

    Much important to understand the difference between DFMEA and PFMEA, and linkage between these.

  • FMEA Team4:26

    Learn how a cross-functional FMEA team of four to six experts drives effective analysis through self-motivated, active participation, authentic communication, and strong leadership champion sponsorship.

  • FMEA Prerequisites4:04

    Identify customer requirements and feedback as inputs for FMEA prerequisites, and ensure team competence and process capability to analyze and improve outcomes using industry best practices.

  • FMEA Approach & Definition of terms9:56

    Identify potential failure modes, effects, and causes using the PFMEA framework, and learn how controls, occurrence, and detection ratings determine risk priority and action plans.

  • PFMEA Columns Linkage6:25

    Understanding the columns FMEA template is very much needed to learn the FMEA approach.

  • Recommended Action Criteria5:47

    Assess recommended actions in PFMEA using severity, occurrence, and detection to decide when to implement controls; explain zone-based criteria and characteristic classifications for regulatory compliance.

  • Priorities of S , O, D while choosing recommended actions6:10

    Prioritize recommended actions by severity, occurrence, and direction to lower risk in the pfmea and control plan, applying design modifications, process changes, and enhanced detection such as automated optical inspection.

  • Severity, Occurrence & Detection Rating Tables17:41

    Explore severity, occurrence, and detection rating tables in PFMEA, learn how RPN guides risk prioritization, and see how primary and secondary functions, regulatory requirements, and detection methods shape safety.

  • PFMEA Example6:59

    Learn here PFMEA approach in practical where you will find the key techniques to define the PFMEA.

  • FMEA
  • Do FMEA analysis for Pizza making process
  • Linkage Of FMEA With Special Characteristics7:17

    Link FMEA with special characteristics by using past failures, lessons learned, and customer input to identify CPCs and translate them into action through system, design, and process FMEA.

Requirements

  • Basic knowledge of FMEA

Description

End of the course you will be able to learn / become Master in create the PFMEA without any error.  That's how course content is developed to understand the each column of PFMEA template and Control plan as per IATF 16949:2016. Course content is designed to learn by all kinds of manufacturing and service industries.

We could call " Effective PFMEA"  only when identified failure modes are not occurred and zero customer / warranty failures. This can be achieved by properly identify the " Requirements" and cascade to analysis. In this course mainly focused on how to feed inputs (requirements), get outputs (Process characteristics) and approach used to define the recommended action. Usually common mistake do by most of the people during rating the secondary SxOxD. Very simple logics applied to selection of secondary SOD ratings.

Another important topic is identify the Special characteristics based on severity rating and classification of characteristics with cascade to control plan for special control.

As per IATF 16949 clause 8.5.1.1 requirement is PFMEA & Control plan shall have linkage. You will learn, logic and idea behind this method. The reason behind the requirement is, every failure mode and cause of failure shall be under control to prevent the occurrence of defect.

Let's access this course to become expert in PFMEA.

Who this course is for:

  • Manufacturing, service industry professionals such as Quality, Process Engineering, Product Designers, Manufacturing Engineers, health care professional etc.,

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