A Framework for Effective Implementation of Process Failure Modes and Effects Analysis with Control Plans to Mitigate Process, Discrete Manufacturing and Service Industries, Using Aerospace Standard Best Practices 2019-28-0149

In Today’s World, Every Manufacturing and Service Industry aims in providing the Highest Quality of Products and Service at the lowest Competitive Cost and timely delivery to its Customers. The Discrete Aerospace Manufacturing and Assembly industry is taking initiatives to implement the Process Failure Modes and Effects Analysis (PFMEA) tool for its critical Aerospace Manufacturing and Assembly suppliers, by implementing Aerospace Standards, in an effort to create a synergy between the End user customers, Original Equipment manufacturers and the suppliers, for ensuring increased safety, quality, reliability for the Aircraft parts and components produced by them. The main aim is to use this concept as a Process Risk Management tool for Identification, Assessment, Mitigation, Control and Prevention of risks associated with Designs and Manufacturing. This method is quite different from conventional FMEA methodology as it focuses on an integrated approach of linking the process flow diagram, followed by a PFMEA again linked with a Control plan to identify and implement controls for measuring and monitoring the process risks. This can identify the manufacturing system’s area of focus of weakness or opportunity, at early stages of production and thereby minimize Cost of Poor Quality by being aware of the risks associated with the increased occurrence of both Internal and External failures such as reworks, repairs, scraps, escapes and turn backs. This case study paper describes the benefits of implementing an effective framework and the current scope of improvement in the methodology and how can it be effectively utilized in any similar critical process industry.