PFMEA Worksheet with RPN for PPAP (Excel Export)
A process FMEA is one of the core documents in a PPAP package and sits between the process flow diagram and the control plan. This worksheet gives you the standard columns, calculates RPN on every row, and exports to Excel or PDF so you can attach it to your submission.
| Process step | Failure mode | Effect of failure | Potential cause | Current control | Severity (1-10) | Occurrence (1-10) | Detection (1-10) | RPN | Action owner | Target date | |
|---|---|---|---|---|---|---|---|---|---|---|---|
112 | |||||||||||
144 | |||||||||||
54 | |||||||||||
36 |
RPN is a prioritisation aid. Many customers, and the AIAG and VDA FMEA handbook, now prefer Action Priority (AP) over a bare RPN threshold, and always review high severity rows regardless of RPN. Use your customer's rating tables.
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How to use the worksheet
Start from your process flow diagram and list each operation as a row, then add every credible failure mode for that step. For each row fill the effect on the customer, the cause, and the controls that exist today. Rate severity, occurrence and detection from 1 to 10 using your customer-approved rating tables. The RPN column multiplies the three ratings automatically. Add rows for each additional cause, because one failure mode often has several causes with different occurrence and detection scores.
- One row per failure mode and cause pair
- Rate severity on the effect, not the cause
- Rate detection on the current control, not the planned one
- Record action owner and date for every high-risk row
RPN and Action Priority
RPN equals severity times occurrence times detection and ranges from 1 to 1000. It is simple, but two very different risks can have the same RPN, for example 9 x 2 x 3 and 3 x 3 x 6. The harmonised AIAG and VDA FMEA approach replaces RPN thresholds with a High, Medium and Low Action Priority table driven mainly by severity. If your customer's customer-specific requirements call for AP, keep RPN as a sorting column only and add the AP rating in your final document.
Reading the example rows
The sample rows show a machined housing. The deburr row has the highest RPN because detection depends on a visual check, which is weak. The wash row has high severity but low RPN because occurrence is low and the cleanliness test is strong. A good reviewer still looks at the wash row, because severity 9 items need documented controls regardless of the product. Overwrite the sample rows with your own process.
Common mistakes and ERP notes
The most common mistake is rating occurrence from opinion instead of data. Use scrap, rework and first pass yield history where you have it. Another is copying an old PFMEA without checking that the process flow still matches. If your ERP or MES holds routings and nonconformance history, pull defect counts per operation to support your occurrence ratings, and keep operation numbers in the PFMEA identical to the routing and control plan.
Frequently Asked Questions
Is RPN still used in PFMEA?
Yes in many plants, but the AIAG and VDA FMEA handbook moved to Action Priority. Check your customer-specific requirements. Even when RPN is used, review every row with high severity, because a low RPN can hide a safety or regulatory failure effect.
What RPN is too high?
There is no universal cutoff. Some customers set 100 or 120 as a trigger, others forbid fixed cutoffs. Treat RPN as a ranking and act on severity first, then on the highest RPN items, and document the actions you took and the re-rated values.
Does the PFMEA need to match the control plan?
Yes. Every significant failure mode and its control in the PFMEA should appear in the control plan, with the same operation numbers and characteristic names. Mismatches are a common reason PPAP submissions are rejected during review.
Can I export this to Excel?
Yes. Use the export buttons to download the table as Excel, CSV or PDF. The RPN column is exported with its calculated values so you can sort and filter in your own workbook.
If your operation numbers, defect history and routings live in an ERP, Netray can help pull them into a PFMEA review that stays in sync with your routing, read-only and on your own infrastructure.
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