Process FMEA is a systematic method to analyze defects
of manufacturing and assembly processes. According to the
VDA framework [10] the method consists of the five steps
structure analysis, function analysis, failure analysis, measure
analysis and optimization. Within the structure analysis the
considered process chain is systematically structured into
individual process elements. In the functional analysis, for
each element of the structure analysis, activities are assigned
necessary for proper function of the process chain. Within the
failure analysis the occurrence of defects within the
manufacturing processes is determined. In the measure
analysis potential defects are classified by the concept of risk
priority numbers (RPN). Depending on the RPN, optimization
measures to reduce quality issues can be implemented [11].
Process FMEA is a very effective and widely used tool to
identify causes of defects and appropriate prevention
measures. Yet, it does not include any visualization of the
process chain regarding the occurrence of defects, inspection
processes or quality control loops. Neither, quality related
costs are taken into account