Process FMEA Risksheet Configuration

Overview

PFMEA differs from System FMEA (SFMEA) and Design FMEA (DFMEA) by analyzing the manufacturing process itself rather than product design. The PFMEA risksheet organizes process analysis into three hierarchical levels:

Level 1: Process Step — the manufacturing operation being assessed (e.g., “Weld Sensor Housing”)
Level 2: Failure Mode — how the process could fail (e.g., “Inadequate weld penetration”)
Level 3: Cause — root cause of the failure (e.g., “Insufficient welding temperature”)

This hierarchy enables drill-down analysis with aggregated risk calculations and supports IATF 16949 control planning requirements.

Hierarchical Structure

Property	Purpose
`hierarchyDefinition.controlColumn`	Column defining level navigation (default: “Character”)
`hierarchyDefinition.zoomColumn`	Column triggering expand/collapse on click
`hierarchyDefinition.collapseTo`	Column used to group causes under failure modes
`hierarchyDefinition.levels[].name`	Level identifier: “Item”, “FailureMode”, “Cause”

Collapse Behavior

The collapseTo property determines how Level 3 (Cause) rows aggregate. When set to the Failure Mode descriptor column, multiple causes collapse into a single grouped row with RPN values summed or rolled up by formula. This supports AIAG-VDA practice of identifying multiple potential causes per failure mode, each with separate occurrence and detection ratings.

Progressive Workflow Views

PFMEA analysis progresses through eight named views, each showing columns relevant to that analysis stage:

View Name	Purpose	Columns Visible
1. Identify Failure Modes	Capture how each process step could fail	Process Step, Failure Mode, Effect, Severity
2. Initial Risk Ranking	Rate occurrence and detection before controls	Severity, Occurrence (pre), Detection (pre), Pre-mit AP
3. Link Upstream SFMEA	Trace to System FMEA failure modes causing this process risk	Upstream Risks (multilink to SFMEA), Pre-mit AP
4. Define Mitigations	Specify prevention and detection controls	Prevention Control, Detection Control, Risk Control (task link)
5. Verify Controls	Document verification that controls are effective	Measurement Method, Sample Frequency, Reaction Plan
6. Final Risk Evaluation	Re-rate occurrence and detection after controls implemented	Occurrence (post), Detection (post), Post-mit AP
7. Risk Summary	Review residual risk and action items	Post-mit AP, Risk Control Status, Summary Notes
Default	Shows all columns (no filtering)	All columns visible
Full View	Complete reference including hidden technical fields	All configuration properties

Use views in sequence: identify → rank → trace → mitigate → verify → evaluate → summarize. Each view filters columns to prevent overwhelming users with all 30+ properties at once.

Column Groups and Configuration

Process Analysis (Level 1)

Property Name	Type	Default	Description
`metadata.productName`	string	”TestAuto2”	Solution name for document branding
`metadata.standardName`	string	”AIAG-VDA FMEA”	Manufacturing standard referenced
`metadata.lastModified`	date	auto	Configuration version timestamp

Process Step Linkage (Level 1)

Property Name	Type	Default	Description
`columnGroups[0].groupName`	string	”Process Step”	Header for Level 1 columns
`columns[].name`	string	”Character”	Process characteristic or step identifier binding to processStep work item via `itemLink` type with `assesses` link role
`columns[].dataType`	string	”itemLink”	Links Level 1 rows to processStep work items
`columns[].linkRole`	string	”assesses”	Relationship type connecting PFMEA to process documentation

Failure Mode Description (Level 2)

Property Name	Type	Default	Description
`columns[].name`	string	”Failure Mode”	How the process could fail; binding to work item description field or `failureMode` custom field
`columns[].dataType`	string	”text” or “field”	Stores failure mode description text or references failureMode work item type
`columns[].fieldName`	string	”failureMode”	Polarion custom field storing failure mode text

Effect and Severity (Level 2)

Property Name	Type	Default	Description
`columns[].name`	string	”Effect of Failure”	Customer-visible or downstream impact of the failure mode (e.g., “Weld leak causes coolant loss”)
`columns[].fieldName`	string	”effectOfFailure”	Custom field capturing effect description; used for severity rating justification
`columns[].name`	string	”Severity”	AIAG-VDA severity rating (1–10) representing severity of failure effect
`columns[].dataType`	string	”enum”	Enumeration type constraining values to 1–10
`columns[].enumName`	string	”fmeaSeverity”	Reference to Severity enumeration (see FMEA Severity (1-10))
`columns[].fieldName`	string	”pfmSeverity”	Polarion custom field; Severity assigned at Level 2 and inherited by all causes

In PFMEA, Severity is assigned once per Failure Mode and does NOT change between pre-mitigation and post-mitigation assessment. Only Occurrence and Detection ratings improve with control implementation. This differs from risk management frameworks where mitigation can reduce severity.

Cause of Failure (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Cause of Failure”	Root cause description at Level 3; binding to causeOfFailure custom field or work item description
`columns[].fieldName`	string	”causeOfFailure”	Stores cause text; multiple causes may exist per failure mode, each with separate RPN
`columns[].dataType`	string	”text”	Free-form root cause description

Prevention and Detection Controls (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Prevention Control”	Design or process control that prevents the cause from occurring (e.g., “Temperature monitoring with alarm”)
`columns[].fieldName`	string	”preventionControl”	Custom field storing prevention control description; justifies low Occurrence rating
`columns[].dataType`	string	”text”	Free-form control description
`columns[].name`	string	”Detection Control”	Inspection or test method that detects failure before reaching customer (e.g., “100% ultrasonic weld inspection”)
`columns[].fieldName`	string	”detectionControl”	Custom field storing detection control description; justifies Detection rating
`columns[].dataType`	string	”text”	Free-form control description

Occurrence and Detection Ratings (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Occurrence (Pre-Control)“	Likelihood of cause occurring BEFORE controls implemented (1–10 scale); rated based on process capability without controls
`columns[].fieldName`	string	”pfmOccurrence”	Custom field; 1=very rare, 10=very frequent; see PFMEA Occurrence
`columns[].enumName`	string	”pfmOccurrence”	Enumeration reference
`columns[].name`	string	”Detection (Pre-Control)“	Ability of current process controls to detect the cause BEFORE reaching customer (1–10 scale); 1=almost certain to detect, 10=certain not to detect
`columns[].fieldName`	string	”pfmDetection”	Custom field; see PFMEA Detection
`columns[].enumName`	string	”pfmDetection”	Enumeration reference
`columns[].name`	string	”Occurrence (Post-Control)“	Occurrence rating AFTER planned controls implemented; remains 1–10 scale but reflects reduced frequency with new process controls
`columns[].fieldName`	string	”pfmOccurrenceNew”	Custom field storing post-control occurrence; recalculated during Step 6 (Final Risk Evaluation view)
`columns[].name`	string	”Detection (Post-Control)“	Detection rating AFTER control verification completed; reflects improved inspection effectiveness or new detection technology
`columns[].fieldName`	string	”pfmDetectionNew”	Custom field storing post-control detection rating

Action Priority Formula

Pre-mitigation and post-mitigation Action Priority (AP) calculated using identical threshold logic applied to Occurrence and Detection ratings:

// Pre-Mitigation Action Priority (commonAP)
function calculateAP(severity, occurrence, detection) {
  // High priority if severe OR high probability OR difficult to detect
  if (severity >= 9) return "H";                          // Very severe failures always High
  if (severity >= 5 && occurrence >= 4) return "H";       // Moderate severity + frequent = High
  if (severity >= 6 && occurrence >= 4 && detection >= 5) return "H";  // Moderate + frequent + hard to detect = High
  
  // Medium priority if any single factor elevated
  if (severity >= 5 || occurrence >= 4 || detection >= 6) return "M";
  
  // Low priority otherwise
  return "L";
}

// Post-Mitigation Action Priority (commonAPNew)
// Same formula applied to Severity (unchanged) + pfmOccurrenceNew + pfmDetectionNew
function calculateAPNew(severity, occurrenceNew, detectionNew) {
  return calculateAP(severity, occurrenceNew, detectionNew);
}

Threshold	High (H)	Medium (M)	Low (L)
Severity	≥9 OR (≥5 AND Occ≥4 AND Det≥5)	≥5 OR Occ≥4 OR Det≥6	Otherwise
Occurrence	≥4 (in context of Sev/Det)	≥4 or elevated factor	<4 and low severity
Detection	≥5 (in context)	≥6 or elevated	<6 and good controls

Pre-mitigation AP (commonAP) assesses risk BEFORE controls, guiding prioritization of which causes require attention. Post-mitigation AP (commonAPNew) uses the SAME severity but updated occurrence/detection ratings AFTER controls are implemented, demonstrating residual risk. If post-mitigation AP remains High despite controls, further actions required.

Special Characteristics Classification (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”SC/CC”	Safety Critical (SC) or Critical Characteristic (CC) classification per IATF 16949 and ISO 26262 requirements
`columns[].dataType`	string	”enum”	Constrained enumeration with values: “SC”, “CC”, “Neither”
`columns[].cellDecorators[].type`	string	”badgeRenderer”	Custom HTML renderer applying color-coded styling
`columns[].cellDecorators[].renderLogic`	code	See below	SC renders orange background (#ff8c00), CC renders red (#c62828)

// SC/CC Badge Renderer
if (value === "SC") {
  return '<div style="background-color: #ff8c00; color: white; padding: 4px 8px; border-radius: 4px; font-weight: bold; text-transform: uppercase;">SC</div>';
}
if (value === "CC") {
  return '<div style="background-color: #c62828; color: white; padding: 4px 8px; border-radius: 4px; font-weight: bold; text-transform: uppercase;">CC</div>';
}
return '';

SC (Safety Critical): Characteristic directly related to functional safety per ISO 26262; failure could lead to ASIL A/B/C/D hazard. Requires ISO 26262 verification and traceability to safety goals.
CC (Critical Characteristic): Characteristic affecting product quality per IATF 16949; failure could result in customer dissatisfaction or warranty cost but not necessarily functional safety impact. Requires IATF control plan rigor (SPC, measurement system analysis, capability studies).

Upstream Risk Traceability (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Upstream Risks (SFMEA)“	Multi-item link column displaying System FMEA failure modes that cause this process failure cause via `causes` relationship
`columns[].dataType`	string	”multiItemLink”	References multiple failureMode work items from System FMEA documents
`columns[].linkRole`	string	”causedBy”	Reverse direction; shows System-level risks that propagate to Process level
`columns[].itemTemplate`	velocity	See below	Renders title, module context, severity for navigation

#set($upstreamFM = $item.getLinkedWorkItems("causedBy"))
#foreach($fm in $upstreamFM)
  <strong>$fm.getTitle()</strong> (Module: $fm.getModule().getModuleId())
  <br/>Severity: $fm.getCustomFieldValue("severity")
#end

Risk Control Task Linking (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Risk Control”	Task link column creating/linking riskControl work items that mitigate this failure cause via `mitigates` relationship
`columns[].dataType`	string	”task”	Embedded work item type; creates riskControl items directly from risksheet with auto-linking
`columns[].linkRole`	string	”mitigates”	Relationship indicating this control mitigates (reduces occurrence or detection risk of) this cause
`columns[].allowCreate`	boolean	true	Users can create new riskControl work items inline; linked automatically
`columns[].taskColumns[]`	array	[“id”, “title”, “status”]	Columns displayed for expanded risk controls showing ID, title, and workflow status

Risk Controls created from PFMEA appear as expandable sub-rows; clicking expand shows control ID, description, assignee, due date, and status. This enables direct assignment of mitigation responsibility without navigating away from the risksheet.

Post-Mitigation Visual Indicators (Level 3)

Property Name	Type	Default	Description
`columns[].name`	string	”Post-Mitigation AP”	Final action priority after controls; rendered with color-coded cell background and row header inheritance
`columns[].cellDecorators[].type`	string	”apRenderer”	Custom renderer applying risk-level colors and labels

// Action Priority Cell Renderer
function renderAP(apValue) {
  if (apValue === "H") {
    return '<div style="background-color: #DC143C; color: white; padding: 8px; text-align: center; font-weight: bold; font-size: 18px; border-radius: 4px;">' +
           '<div style="font-size: 14px;">H</div><div style="font-size: 11px;">High</div></div>';
  }
  if (apValue === "M") {
    return '<div style="background-color: #FF8C00; color: white; padding: 8px; text-align: center; font-weight: bold; font-size: 18px; border-radius: 4px;">' +
           '<div style="font-size: 14px;">M</div><div style="font-size: 11px;">Medium</div></div>';
  }
  if (apValue === "L") {
    return '<div style="background-color: #4CAF50; color: white; padding: 8px; text-align: center; font-weight: bold; font-size: 18px; border-radius: 4px;">' +
           '<div style="font-size: 14px;">L</div><div style="font-size: 11px;">Low</div></div>';
  }
}

// Row Header Color Inheritance (rowHeaderAPNew)
// Row header background inherits color from Post-Mitigation AP value for global risk visibility
if (row.postMitigationAP === "H") rowHeader.style.backgroundColor = "#DC143C";
if (row.postMitigationAP === "M") rowHeader.style.backgroundColor = "#FF8C00";
if (row.postMitigationAP === "L") rowHeader.style.backgroundColor = "#4CAF50";

Red row headers indicate unresolved High residual risk. Orange headers identify Medium priorities requiring planned mitigation. Green headers show fully controlled Low-risk causes. This color gradient enables instant visual assessment of PFMEA completion status without reading text.

Data Type Definitions

ItemLink (Level 1 Process Step)

{
  "name": "Character",
  "dataType": "itemLink",
  "fieldName": "itemLink",
  "linkRole": "assesses",
  "targetWorkItemType": "processStep",
  "renderTemplate": "<strong>${item.title}</strong> (ID: ${item.id})"
}

Process Step work items must exist before PFMEA analysis. Each Level 1 row links to exactly one processStep item representing the manufacturing operation.

MultiItemLink (Upstream SFMEA)

{
  "name": "Upstream Risks (SFMEA)",
  "dataType": "multiItemLink",
  "linkRole": "causedBy",
  "backLink": false,
  "targetWorkItemType": "failureMode",
  "renderTemplate": "<strong>${item.title}</strong> from ${item.module.name} (Severity: ${item.severity})",
  "allowMultiple": true
}

Multiple System FMEA failure modes may cause a single Process FMEA cause, representing cascade risk propagation.

Task (Risk Controls)

{
  "name": "Risk Control",
  "dataType": "task",
  "linkRole": "mitigates",
  "workItemType": "riskControl",
  "allowCreate": true,
  "taskColumns": ["id", "title", "assignee", "dueDate", "status"],
  "createDefaultFields": {
    "title": "Control for ${failureMode}",
    "priority": "High"
  }
}

Risk controls created inline appear as expandable sub-items. Each control links via mitigates relationship.

Integration with Other Risksheets

System FMEA (SFMEA) → Process FMEA (PFMEA)

SFMEA identifies design-level failure modes; PFMEA translates those into manufacturing process risks. The Upstream Risks column enables traceability from PFMEA cause → SFMEA failure mode, documenting how process failures could manifest product-level defects.

System FMEA (Cause) → Process FMEA (Cause) via causedBy relationship. This ensures process controls address root causes identified at design level.

Process FMEA (PFMEA) → Control Plan

After PFMEA causes are identified and rated, Control Plan document formalizes manufacturing controls using controlPlanItem work items. Control Plan captures:

Product Characteristics (links to characteristics work items)
Process Parameters (links to processStep work items)
Measurement Method (inspection/test technique)
Sample Frequency and Size (statistical sampling plan)
Reaction Plan (corrective action for out-of-control situations)

See Control Plan Risksheet Configuration for detailed control plan configuration.

Required Work Item Types

PFMEA risksheet requires these work item types exist in the Polarion project:

Type	Purpose	Created By
`processStep`	Manufacturing operation being analyzed (Level 1)	Process documentation import; linked from PFMEA Level 1
`failureMode` (or custom field binding)	Stores failure mode text for Level 2	PFMEA risksheet users
`riskControl`	Mitigation controls linked via `mitigates` relationship	PFMEA risksheet users (inline creation)
`characteristic`	Optional; linked from Process FMEA for characteristics-based PFMEA variants	Design/Requirements team

See Process Step, Risk Control, and Control Plan Item work item type reference pages.

Custom Fields Required

Field Name	Type	Description	Used In
`failureMode`	text	Failure mode description (Level 2)	Multiple causes may share same failure mode
`effectOfFailure`	text	Customer-visible impact	Justifies severity rating
`causeOfFailure`	text	Root cause (Level 3)	Unique per row
`preventionControl`	text	Controls preventing cause	Justifies pre-control occurrence rating
`detectionControl`	text	Inspection/test detecting failure	Justifies pre-control detection rating
`pfmSeverity`	enum (fmeaSeverity: 1–10)	Severity rating (unchanged pre/post)	Assigned at Level 2
`pfmOccurrence`	enum (pfmOccurrence: 1–10)	Pre-control occurrence	Initial risk assessment
`pfmDetection`	enum (pfmDetection: 1–10)	Pre-control detection	Initial risk assessment
`pfmOccurrenceNew`	enum (pfmOccurrence: 1–10)	Post-control occurrence	Final risk evaluation
`pfmDetectionNew`	enum (pfmDetection: 1–10)	Post-control detection	Final risk evaluation
`scccClassification`	enum	SC/CC/Neither	Supports IATF 16949 control plan requirements

See Process Step Custom Fields for field definitions.

Version Information

Property	Value
Configuration Format	risksheet.json v3.0
AIAG-VDA FMEA Edition	2nd Edition (2008)
IATF 16949:2016 Edition	2016
ISO 26262 Edition	2018 (Edition 2)
Last Updated	2026-02-15

For complete Process FMEA workflow guidance, see:

Create Process FMEA Document — Step-by-step workflow
Define Failure Modes — Failure mode analysis techniques
Assess Severity, Occurrence, Detection — Rating methodology
Calculate Action Priority — AP threshold logic
Link to Risk Controls — Mitigation workflow
System PFMEA Report — Reporting and compliance evidence
AIAG-VDA FMEA Methodology — Standards compliance context
Action Priority Methodology — H/M/L decision logic
Control Plan Risksheet Configuration — Downstream control planning

Getting Started

Concepts

Reference

Guides

Troubleshooting

FAQ

Process FMEA Risksheet Configuration

Overview

Hierarchical Structure

Collapse Behavior

Progressive Workflow Views

Column Groups and Configuration

Process Analysis (Level 1)

Process Step Linkage (Level 1)

Failure Mode Description (Level 2)

Effect and Severity (Level 2)

Cause of Failure (Level 3)

Prevention and Detection Controls (Level 3)

Occurrence and Detection Ratings (Level 3)

Action Priority Formula

Special Characteristics Classification (Level 3)

Upstream Risk Traceability (Level 3)

Risk Control Task Linking (Level 3)

Post-Mitigation Visual Indicators (Level 3)

Data Type Definitions

ItemLink (Level 1 Process Step)

MultiItemLink (Upstream SFMEA)

Task (Risk Controls)

Integration with Other Risksheets

System FMEA (SFMEA) → Process FMEA (PFMEA)

Process FMEA (PFMEA) → Control Plan

Required Work Item Types

Custom Fields Required

Version Information

Getting Started

Concepts

Reference

Guides

Troubleshooting

FAQ

​Overview

​Hierarchical Structure

​Collapse Behavior

​Progressive Workflow Views

​Column Groups and Configuration

​Process Analysis (Level 1)

​Process Step Linkage (Level 1)

​Failure Mode Description (Level 2)

​Effect and Severity (Level 2)

​Cause of Failure (Level 3)

​Prevention and Detection Controls (Level 3)

​Occurrence and Detection Ratings (Level 3)

​Action Priority Formula

​Special Characteristics Classification (Level 3)

​Upstream Risk Traceability (Level 3)

​Risk Control Task Linking (Level 3)

​Post-Mitigation Visual Indicators (Level 3)

​Data Type Definitions

​ItemLink (Level 1 Process Step)

​MultiItemLink (Upstream SFMEA)

​Task (Risk Controls)

​Integration with Other Risksheets

​System FMEA (SFMEA) → Process FMEA (PFMEA)

​Process FMEA (PFMEA) → Control Plan

​Required Work Item Types

​Custom Fields Required

​Version Information

​Related Reference Pages

Overview

Hierarchical Structure

Collapse Behavior

Progressive Workflow Views

Column Groups and Configuration

Process Analysis (Level 1)

Process Step Linkage (Level 1)

Failure Mode Description (Level 2)

Effect and Severity (Level 2)

Cause of Failure (Level 3)

Prevention and Detection Controls (Level 3)

Occurrence and Detection Ratings (Level 3)

Action Priority Formula

Special Characteristics Classification (Level 3)

Upstream Risk Traceability (Level 3)

Risk Control Task Linking (Level 3)

Post-Mitigation Visual Indicators (Level 3)

Data Type Definitions

ItemLink (Level 1 Process Step)

MultiItemLink (Upstream SFMEA)

Task (Risk Controls)

Integration with Other Risksheets

System FMEA (SFMEA) → Process FMEA (PFMEA)

Process FMEA (PFMEA) → Control Plan

Required Work Item Types

Custom Fields Required

Version Information

Related Reference Pages