Consulting

FMEA & Control Plan review: documents that match the line.

A PFMEA written in a meeting room often misses what really goes wrong on the floor. This review checks your FMEA and control plan against the actual process, and shows where they don't match.

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  • Remote or on site, depending on need
  • Typically 2–3 days per product family, depending on process, routing, criticality and scope
  • NDA signed on request

Is this for you?

  • Your PFMEA and control plan were copied from another product or a template.
  • A customer or auditor has questioned your FMEA, or a defect escaped that the FMEA never mentioned.
  • You're moving from the AIAG 4th edition format to AIAG-VDA, and want it done properly, not just reformatted.

What you get

  • A review of your DFMEA and/or PFMEA in AIAG or AIAG-VDA format
  • A check of the control plan against the PFMEA and against the floor
  • A clear list of gaps: missing failure modes, weak controls, ratings that don't hold up, controls that aren't really done
  • A review session with your team, so they learn the reasoning, not just the corrections

How it works

  1. Share the documents (under NDA if you need one).
  2. Desk review: a close look at the FMEA and control plan structure and logic.
  3. Floor check: the documents are compared with the real process, on site or remotely with photos and video.
  4. Review session: we go through the findings with your team and agree the changes.

What changes afterwards

Your FMEA and control plan describe the process you actually run. Your team understands why each change was made, so the documents stay alive.

Questions people ask

AIAG or AIAG-VDA?

Both. The review follows the format your customer requires.

Will you rewrite our FMEA?

The review shows what to change and why. If you need hands-on help updating it, we can agree that separately.

Further reading

Discuss an FMEA review

Let's talk about what's happening on your floor.

A short message is enough. You'll get a reply within one working day.

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