AS13004 PFMEA and Control Plan

Create and maintain a linked Process Flow Diagram, Process Failure Mode and Effects Analysis, Control Plan, action register and supporting approval records throughout the manufacturing-process lifecycle.

PFMEA Guidebook Download Understanding PFMEA – Training Publication PFMEA Workbook (Excel) Form

Unsaved PFMEA

0 PFMEA rows

AS13004A defines a lifecycle methodology linking Process Flow Diagrams, PFMEA and Control Plans. This tool supports creation and traceability of those records but does not reproduce proprietary standard text or replace customer-specific requirements.

PFMEA is one part of a connected process-control system — maintain the links, not just the document.

1Process Flow DiagramWhat the process does

2PFMEAWhat could go wrong

3Control PlanHow risk is controlled

4Process ControlsHow controls are executed

5Feedback & LearningEscapes, changes, capability & lessons

Closed-loop principle: production feedback and learning should drive updates back into the Process Flow, PFMEA and Control Plan throughout the lifecycle.

PFMEA Header and Scope

Organisation / Site

Customer

Programme / Project

Customer Approval / Reference

Part / Family Name

Part Number / Family

Drawing / Design Revision

Manufacturing Site

PFMEA Number

PFMEA Revision

Original Issue Date

Current Revision Date

AS13004 Revision

Lifecycle Phase

PFMEA Status

Confidentiality / Export Control

Scope, Boundaries and Intended Manufacturing Process

Assumptions, Interfaces and Exclusions

PFMEA Summary

0Process steps

0Failure-mode rows

0High-priority risks

0Open actions

Multidisciplinary PFMEA Team

Record functions involved in developing, reviewing and maintaining the process risk analysis.

Name	Function / Discipline	Organisation	Role	Competence / Experience	Approval / Initials

Design engineering represented

Manufacturing engineering represented

Production represented

Quality represented

Special process / technical experts represented

Supplier / customer input considered

Process Flow Diagram Record

Define process sequence, movement, storage, inspection and outsourced operations. Step IDs link directly to PFMEA and Control Plan rows.

Step ID	Operation / Process Step	Type	Inputs	Outputs / Requirements	Equipment / Tooling	Location / Supplier	Special / Key Characteristics	Flow Reference

Process Flow Diagram Number

PFD Revision

PFD File / Drawing Reference

Process Flow Notes and Interfaces

Process Failure Mode and Effects Analysis

Use one row for each failure mode and cause combination. Ratings and RPN recalculate automatically.

ID	Step ID	Process Function / Requirement	Potential Failure Mode	Potential Effect(s)	S	Classification	Potential Cause / Mechanism	O	Current Prevention Controls	Current Detection Controls	D	RPN	Priority	Recommended Action	Owner	Target Date	Action Status	Action Taken / Evidence	New S	New O	New D	New RPN	Residual Priority

High-priority RPN Threshold

Medium-priority RPN Threshold

Mandatory Severity Review Level

Risk Escalation / Approval Rule

PFMEA Review Notes

Control Plan

Link controls to process-flow and PFMEA identifiers, including reaction and containment requirements.

Control ID	Step ID	PFMEA ID	Operation	Product / Process Characteristic	Classification	Specification / Tolerance	Evaluation / Measurement Technique	Gauge / Tool ID	Sample Size	Frequency	Control Method	Reaction Plan	Containment / Escalation	Record	Owner

Control Plan Number

Control Plan Revision

Control Plan Phase

Reaction Plan Reference

Risk Reduction and Action Register

This register can include actions generated directly from PFMEA rows and wider process-risk reviews.

Action ID	PFMEA / Control Reference	Action Description	Action Type	Owner	Target Date	Status	Completion Date	Evidence / Record	Effectiveness Verification	Approved By

Revision and Change History

Revision	Date	Reason / Trigger	Change Description	Affected PFD / PFMEA / CP IDs	Originator	Approval

Severity Rating Criteria

Edit criteria to match the organisation’s approved AS13004 implementation and customer rules.

Rating	Effect / Consequence Criterion	Safety / Regulatory Consideration	Customer / Product Impact	Manufacturing Impact

Occurrence Rating Criteria

Rating	Occurrence Criterion	Indicative Frequency / Evidence	Process Capability / History

Detection Rating Criteria

Rating	Detection Criterion	Control Effectiveness / Timing	Evidence / Validation

Review Triggers and Lifecycle Maintenance

New product or process introduction

Design, drawing or requirement change

Manufacturing process or supplier change

Nonconformance, escape or customer complaint

Capacity, tooling or equipment change

Periodic review completed

Last Formal Review

Next Review Due

Review Trigger / Reference

Lessons Learned Reference

Preparation, Review and Approval

PFMEA Team Leader

Date

Manufacturing Engineering Approval

Date

Quality Approval

Date

Design Authority Approval

Date

Operations Approval

Date

Customer Approval

Date

Approval Conditions / Outstanding Actions

Document Pack PDF

Save the complete professional PDF pack or choose an individual section. PDF output is generated directly from the data, so all text is wrapped and tables are formatted for the page rather than captured from scrollable screen content.

Document to Save

Supporting Document Register

Document Type	Document Number / File	Revision	Description	Owner	Status	Location / Link Reference