Prima Strategies

"We work with organizations to achieve operational and process excellence"

Failure Mode and Effects Analysis: FMEA


Process Failure Mode and Effects Analysis (PFMEA) is an analysis of risk, applying conventional FMEA methodology to processes in any organization. The primary purpose of FMEA is to prevent potential failure modes from occurring through the use of preventive controls. Process failure modes can lead to safety risks, customer complaints, unplanned operation downtime, reduced output etc. Documenting the FMEA with the use of robustness linkages will help identify the adequacy of existing controls associated with a potential process/operation failure. Finally, improved preventive controls can be recommended to eliminate or mitigate the risks associated with potential failure modes to new and existing processes.

FMEA is a process where management plays an integral role.

The success and quality of FMEAs is directly related to the level of management support and involvement in the process.

Participants to this Process FMEA Application course will be guided to develop FMEAs by using actual workplace process examples.

For example, what could be the potential failure modes related to a new or existing process? What are the potential process failure modes related to its main process steps? What are the potential causes to the failure mode and what are the current process controls to detect the potential cause/mechanism of failure mode or the failure mode itself?

This course will require much interaction among team members; they will demonstrate skills on how to develop and document the FMEA, evaluate the adequacy of proposed controls and the need to mitigate risk by changes that they will have to make to the process controls.

Participants will demonstrate, through team activities and presentations how the recommended actions in their Process FMEAs serve to prevent failures from reaching the customers and ultimately improving customer satisfaction by making FMEA a key process improvement tool.

This course is consistent with the requirements for FMEA development as documented in the Automotive Industry Action Group (AIAG) 4th Edition reference manual.


The course will use relevant process examples to facilitate learning and transfer of knowledge. Participants should be able to effectively deploy the use of FMEA upon completion of this course and make FMEA a key process improvement tool at their workplace. 

At the end of this training, participants will be able to:

  • Apply the FMEA process to identify potential process failures for new or changed process requirements
  • Assess risk associated with each process/operation step
  • Recommend preventive controls to assist with eliminating or significantly reducing the occurrence/re-             occurrence of internal and external customer complaints
  • Substantiate the completed FMEA through the use of robustness linkages for Process FMEA and                   alternative analyses such as Macro and Micro Flow Charting, Verb Noun Analysis, Sentencing Technique       and Characteristics Matrix.
  • Develop, document and review FMEAs and its linkages at appropriate stages of a process lifecycle.
  • Apply the FMEA document on-the-job.


This course is recommended for personnel who will benefit from developing and deploying FMEA.


2 Days

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