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Field Reference

NameTypeDefaultDescription
processInputsText(empty)Captures the inputs required for the manufacturing or assembly process step, enabling input-process-output (IPO) analysis for process FMEA. Identifies raw materials, components, or energy sources consumed by the process.
processOutputsText(empty)Captures the outputs produced by the manufacturing or assembly process step, enabling verification that outputs meet specification. Identifies finished products, assemblies, or intermediate goods produced by the process.
processEquipmentText(empty)Identifies equipment and tooling used in the process step, supporting equipment-based failure mode analysis and preventive maintenance planning. Lists machinery, fixtures, measurement instruments, or assembly tools.
processVerificationText(empty)Defines how process outputs are verified or controlled during manufacturing, bridging process steps to control plan methodology. Summarizes the verification/control strategy (inspection points, measurement locations, acceptance criteria).
linkedSystemElementLink(none)Links process steps to the system elements (components, subsystems) they produce or assemble, enabling traceability from manufacturing process to product architecture. Relationship type: systemElements (bidirectional).

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Process Step Hierarchy and Traceability

Process Steps represent manufacturing or assembly operations in the V-model’s downstream production phase. They form a critical bridge between design specifications and manufacturing controls: diagram
Process Steps describe how products are manufactured or assembled. They capture the operational steps in production sequences (welding, assembly, inspection, packaging) rather than design characteristics. Each Process Step must link to at least one System Element it produces or assembles.

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Input-Process-Output (IPO) Analysis

The three core descriptor fields (processInputs, processOutputs, processEquipment) implement the IPO framework used in process FMEA analysis:
PhaseFieldPurposeExample
InputprocessInputsMaterials/components entering the process”Sensor housing (plastic), camera module (electronics), assembly adhesive”
ProcessprocessEquipmentEquipment/tooling used in transformation”Ultrasonic welder, IR heat fixture, automated assembly robot”
OutputprocessOutputsFinished goods leaving the process”Assembled sensor unit, electrical harness, protective housing”
When defining failure modes in PFMEA Risksheet, each process step’s IPO structure informs failure mode identification:
  • Input failures: Defective incoming material, wrong component lot, contamination
  • Process failures: Equipment malfunction, tooling wear, parameter drift, operator error
  • Output failures: Nonconforming assembly, damaged component, specification violation
All three fields (processInputs, processOutputs, processEquipment) should be populated before linking Process Steps to PFMEA failure modes. Incomplete IPO descriptions result in missed failure mode categories in risk analysis.

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Process Verification and Control Plan Integration

The processVerification field bridges Process Steps to the detailed control planning methodology defined in Control Plan Items. This field provides a high-level summary of how the process is controlled: Control Plan Item Custom Fields:
Control Plan FieldRelates toPurpose
measurementTechniqueprocessVerificationSpecific measurement method (e.g., “Ultrasonic thickness gauge”, “Visual inspection per ANSI standard”)
sampleSizeprocessVerificationNumber of items inspected per sampling event (e.g., “5 consecutive units”)
sampleFrequencyprocessVerificationInspection frequency (e.g., “Every 100 units”, “Continuous”, “Shift-end”)
controlMethodprocessVerificationControl technique to maintain stability (e.g., “Real-time SPC with X-bar/R chart”, “Capability study”)
reactionPlanprocessVerificationCorrective actions when limits are exceeded (e.g., “Halt production, adjust parameters, run capability study”)
Example processVerification entry: 
Verification: 100% automated optical inspection + sample ultrasonic thickness measurement
every 50 units. Response: If thickness out of spec, adjust pressure on welder and retest batch.
The Process Steps PowerSheet configuration displays Process Steps alongside linked System Elements in a side-by-side traceability view. This enables validation that all manufacturing processes map back to product architecture elements and supports design-change impact analysis (design changes may require process revalidation).

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System Element Linkage

Process Steps must be linked to one or more System Elements via the linkedSystemElement field using the systemElements link role. This linkage establishes traceability from manufacturing process back to product design: Linkage Pattern: Traceability Validation:
  • Every System Element should have at least one associated Process Step describing how it is manufactured
  • Every Process Step should link to at least one System Element it produces
  • Design changes to a System Element (characteristic, tolerance, material) may impact linked Process Steps (measurement methods, control limits, reaction plans)
Impact Analysis Example: diagram
The systemElements link role is bidirectional in the RTM model. When you create a Process Step and link it to a System Element, the System Element work item shows a reverse link to the Process Step. Always validate both directions when updating linkages.

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Process Step in PFMEA Workflow

Process Steps are Level 1 items in the PFMEA Risksheet hierarchy. Each Process Step hosts multiple Failure Modes (Level 2), each with associated Causes (Level 3): PFMEA Hierarchy:
  • Process Step (e.g., “Sensor Housing Assembly”)
    • Failure Mode (e.g., “Adhesive bond line void”)
      • Cause (e.g., “Air trapped between surfaces during assembly”)
The PFMEA Risksheet uses the assesses link role to attach failure modes to process steps: When a failure mode is identified in PFMEA:
  1. Start from Process Step - Select the affected manufacturing operation
  2. Define Failure Mode - How could the process output fail to meet spec?
  3. Identify Causes - Why could this failure occur? (equipment, material, operator, method, environment)
  4. Assess Pre-Mitigation Severity - Customer impact if failure reaches production
  5. Assess Occurrence - Likelihood of cause occurring without detection
  6. Assess Detection - Ability of current controls to catch the defect
  7. Calculate Action Priority (RPN or criticality) - Drives risk mitigation priority
  8. Define Risk Controls - Actions to reduce occurrence or improve detection
  9. Reassess Post-Mitigation - Verify risk reduction effectiveness
PFMEA focuses on manufacturing and assembly processes, not design. It identifies failures in how products are made, including equipment issues, material variability, process drift, and operator error. It complements DFMEA (design failures) and SFMEA (system failures).

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Process Step Configuration

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Creating a Process Step

  1. Identify Manufacturing Process - List all assembly/manufacturing steps in the production sequence
  2. Populate IPO Fields:
    • processInputs: Raw materials, components, consumables (e.g., adhesive, solvents)
    • processEquipment: Machinery, fixtures, measurement instruments, assembly tools
    • processOutputs: Finished goods, intermediate assemblies, packaged products
  3. Define Verification Strategy - Populate processVerification with inspection/control methods
  4. Link to System Elements - Connect Process Step to the component(s) or subsystem(s) it produces using linkedSystemElement

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Example Process Step Configuration

Work Item Type: Process Step
ID: PS-001
Title: Sensor Housing Assembly and Adhesive Bonding
FieldValue
processInputsSensor housing plastic injection-molded shell (40mm × 30mm × 15mm, ABS per spec), camera module electronics (pre-tested), IR heat seal adhesive (two-part epoxy, <2% void requirement)
processOutputsAssembled sensor unit ready for electrical integration (housing + camera bonded, void-free interface, full electrical continuity)
processEquipmentAutomated ultrasonic welder (1kHz, 100W power), IR heat fixture (controlled to ±5°C), vision inspection system with 0.5mm defect resolution, hardness tester for adhesive cure validation
processVerification100% automated vision inspection for voids and misalignment, sample ultrasonic thickness measurement every 50 units, hardness verification every shift, SPC monitoring of adhesive temperature during cure
linkedSystemElementSensor Housing Assembly (component in Sensor & Housing Subsystem)

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PowerSheet Display Configuration

The Process Steps PowerSheet displays Process Step work items alongside linked System Elements in a two-section RTM view: Column Groups:
  • Process Steps (dark green theme): ID, Title (bold, focused, ascending sort), Description
  • System Elements (dark green theme): ID, Title (bold, linked), Description
RTM Expansion Pattern: 
entityType: ProcessStep
orderBy: title asc

columns:
  - field: id
    title: ID
  - field: title
    title: Title
    formatter: boldTitle
    hasFocus: true
    sort: asc
    collapseTo: true
  - expand: systemElements.systemElement
    columns:
      - field: id
        title: System Element ID
      - field: title
        title: System Element Title
        formatter: boldTitle
When a Process Step links to multiple System Elements (e.g., assembly that involves both Camera Module and Housing), the PowerSheet renders all linked elements in a single row with comma-separated or line-break formatting. This shows the cardinality of the process-to-element relationship.

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Configuration Dependencies and Validation

Required Relationships Before PFMEA:
  • Process Step must link to at least one System Element (linkedSystemElement must have a value)
  • Process Step should have processVerification populated (enables Control Plan traceability)
  • System Elements should be defined in the RTM model (required for bidirectional linkage to work)
Validation Checklist:
  • ✓ All Process Steps have IPO fields populated (processInputs, processEquipment, processOutputs)
  • ✓ All Process Steps link to at least one System Element
  • ✓ Process Step titles are descriptive (e.g., “Sensor Housing Assembly” not just “Assembly”)
  • ✓ Linked System Elements exist in the current system architecture
  • ✓ Process Step sequence matches manufacturing work instructions
  • ✓ processVerification field references actual measurement/control methods used
Before starting PFMEA analysis, run a consistency check to ensure all Process Steps have system element linkages. Unlinked Process Steps cannot be properly analyzed for design impact or included in coverage metrics.

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Cross-Reference