Step 6 – Develop Corrective Actions
Objective:
In this chapter, you’ll learn how to develop effective corrective actions within the PFMEA process to address potential failures by reducing severity, occurrence, and improving detection.
What Are Corrective Actions?
Corrective actions are the steps taken to address and reduce the risks identified in PFMEA. These include:
Reducing the severity of failure effects
Decreasing the likelihood of occurrence
Improving detection capabilities before the failure reaches the customer
1. How to Reduce Risk Levels?
| Risk Element | Strategy |
|---|---|
| Severity | Modify product or process design |
| Occurrence | Eliminate root causes |
| Detection | Improve monitoring and inspection tools |
2. Assigning Responsibilities and Deadlines
Each action must have a designated person responsible.
Set realistic deadlines to ensure implementation happens on time.
3. Preventive Measures
In addition to corrective actions, you should apply preventive measures like:
Training: Educating staff to avoid common mistakes
Automation: Using machines or systems to reduce human error
Process Improvements: Updating SOPs and workflows for consistency
Step 7 – Monitor and Update PFMEA
Objective:
PFMEA is a dynamic tool and must be monitored and updated regularly. In this chapter, you’ll learn how continuous improvement and structured methods like PDCA help keep PFMEA effective and current.
The Role of Continuous Improvement
PFMEA should be treated as a living document that evolves with process and product changes. Update the document whenever:
A process or design change occurs
New failure modes are identified
Customer complaints or feedback are received
The PDCA Cycle – A Proven Model
The Plan-Do-Check-Act (PDCA) cycle is a structured way to manage and evaluate corrective actions:
Plan: Identify the issue and plan an action
Do: Implement the action
Check: Evaluate the effectiveness of the action
Act: Make necessary adjustments and standardize the solution
Best Practices for Updating PFMEA
Review PFMEA during design revisions
Update after process audits or nonconformities
Use it to capture learnings from customer feedback
Involve a cross-functional team for well-rounded input
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