Module 16 · Quality
Design and process FMEA built on the AIAG-VDA 7-step method. Structure, functions and failure chains are real linked records — not rows in a spreadsheet — so Action Priority updates as you rate, a DFMEA change re-rates the PFMEA behind it, and each control carries straight into the Control Plan.
What it does
Six capabilities, each tied to a decision your team is already trying to make.
Planning, structure, function, failure, risk, optimisation and documentation — one workspace with a stepper, structure tree, function net and failure net. The method is the workflow, so the team follows it without a facilitator policing the template.
Block and boundary diagrams, P-diagrams and a design risk grid for DFMEA. Process steps and 4M work elements for PFMEA. Monitoring and system response for FMEA-MSR. One module, one set of rating tables, three analyses.
Rate Severity, Occurrence and Detection against your own rating tables and Action Priority appears the moment you type. An AP High chain needs an action or a written justification, and the highest-severity chains queue for management review.
A PFMEA effect adopted from the DFMEA keeps following it. Raise a design severity and the process chains behind it are re-rated and flagged for review — no more two documents quietly disagreeing about the same failure.
Prevention and detection actions carry an owner, a due date, a predicted rating and a confirmed rating. A proposed control becomes a current control only when its action is completed — so the FMEA shows the risk you have, not the risk you planned.
Start every new program from a foundation FMEA instead of last year's copy. When the foundation changes, each FMEA built on it shows the changes to review — lessons learned reach every program that needs them.
Follow any characteristic from the DFMEA to the PFMEA, its controls, the Control Plan row and the PPAP evidence. Gaps are flagged on screen: a required special characteristic that was never classified, a severity 10 chain with no characteristic behind it.
Suggested causes, effects and controls drawn from your own FMEAs, CAPAs and lessons learned — each with a citation and a confidence. No external LLM is used in this module, and nothing is written until an engineer accepts it.
Standards & Compliance
Better Together
Zometric's modules share a single data backbone — adopting more of them compounds the signal-to-noise advantage.
The process backbone — every step defined once and shared by the PFMEA and the Control Plan, as a table and as a diagram.
Control Plans generated from the PFMEA and kept in sync — prototype, pre-launch and production, all the way down to the station.
One 8D problem-solving engine for complaints, audit findings and internal issues — from containment to verified effectiveness.
Programs, gates and deliverables on APQP 3rd edition — with status read live from the FMEA, Control Plan and PPAP instead of typed into a tracker.
A 30-minute discovery call. A 2–3 week pilot on real factory data. Then scale at your pace.
