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Free Process FMEA (PFMEA) Template

An AIAG FMEA-4 format Process FMEA worksheet with the complete 12-column matrix — Process Step, Potential Failure Mode, Effect, Severity, Cause, Occurrence, Current Controls, Detection, RPN, Recommended Action, Responsibility, and New S/O/D/RPN. Includes Severity, Occurrence, and Detection rating reference tables. Generated instantly, no login required.

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How to use this template

  1. Complete the header — fill in part number, process name, core team, revision, and dates. The FMEA header must be updated every time the form is revised.
  2. List each process step — break the process into discrete operations (e.g., raw material receipt, machining, heat treat, assembly). Each operation gets its own row set.
  3. Identify potential failure modes — for each process step, ask: "In what ways could this step fail to meet its requirement?" List all potential failure modes, not just the most likely.
  4. Assess Severity (S) — rate the severity of the effect on the customer or end user using the 1–10 AIAG scale. Severity is a property of the effect, not the failure mode.
  5. Rate Occurrence (O) and Detection (D) — Occurrence rates how often the cause leads to the failure mode. Detection rates how likely the current controls are to catch it before reaching the customer.
  6. Calculate RPN and prioritize — RPN = S x O x D. Prioritize all items with RPN >= 100 or Severity >= 9 for corrective action, regardless of RPN.
  7. Record recommended actions — every high-RPN item needs a specific, time-bound action with an owner. Recalculate S/O/D/RPN after implementation to verify improvement.

FMEA Tip: IATF 16949 and AIAG require FMEAs to be "living documents" — updated after each process change, customer complaint, or field failure. Link your PFMEA to your Control Plan and Process Flow Diagram using consistent characteristic numbers.

What's inside the template

1

FMEA Header

Part number, process name, FMEA number, revision, core team, and key dates

2

FMEA Matrix (12-column AIAG format)

Process Step, Failure Mode, Effect, Severity, Cause, Occurrence, Current Controls, Detection, RPN, Recommended Action, Responsibility, New S/O/D/RPN — with 5 pre-filled example rows

3

Severity (S) Reference Table

AIAG 1–10 Severity scale with effect descriptions and rating criteria

4

Occurrence (O) Reference Table

AIAG 1–10 Occurrence scale with failure rate ranges and Cpk equivalents

5

Detection (D) Reference Table

AIAG 1–10 Detection scale with detection method descriptions

6

FMEA Notes

RPN threshold guidance, priority rules for Severity >= 9, and revision instructions

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