PFMEA Template Excel, Process FMEA, RPN Priority Rules, Risk Matrix, Verified Corrective Action Tracker

What can go wrong in your process, which risks come first – and are your actions really reducing them? A process FMEA in Excel that keeps the risk honest.

✔ RPN + High / Medium / Low priority from your own rules
✔ High severity never hidden by a low RPN
✔ Verified risk counts only actions proven effective
✔ Instant download: BLANK + EXAMPLE · Quick Start PDF
✔ Built by a production manager · one-time purchase, no subscription, no macros

▶ Requires Microsoft Excel 2016 or newer on a computer (Windows or Mac). Not for Google Sheets, Apple Numbers or mobile apps.

Customers and auditors ask for a PFMEA. Most teams keep it in a copied spreadsheet: RPN only, actions without owner or date, "Done" without evidence – and a risk that looks lower on paper than on the shop floor. This template rates every failure mode, sets the priority from rules you control, tracks the actions and only shows a lower risk when the action is done AND verified effective. Built by a production manager who works with food-safety and quality audits.

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WHAT IT DOES
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• One row per failure mode and cause: process step, function, failure mode, effect, severity, special characteristic, cause, prevention controls, occurrence, detection controls, detection
• RPN = S × O × D and priority High / Medium / Low from editable rules (severity with occurrence, RPN thresholds)
• High-severity rule: S ≥ 9 is never lower than Medium (or High – your choice), even with a low RPN
• Actions: recommended action, owner, due date, status, what was really done, completion date
• Re-rating after the action = TARGET; the risk NOW only changes when the action is Done with complete data AND verified effective with evidence
• Every row checked: all missing fields listed at once – e.g. action without owner or date, Done without new ratings, verified without evidence, completion date in the future, high severity not marked special, overdue
• Dashboard: priority before / target / now, verified risk reduction, top 10 risks, high-severity list (always visible), open actions and verifications by due date, actions per owner, risk per process step, severity × occurrence risk matrix
• PRINT sheet: printable PFMEA sorted by process step · REVISIONS log

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WHAT'S INCLUDED (ZIP)
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• SmartFactoryTools_PFMEA_Template_v1.0_BLANK.xlsx – your own PFMEA with preset 1–10 scales, priority rules and owners
• SmartFactoryTools_PFMEA_Template_v1.0_EXAMPLE.xlsx – fictional 38 mm beverage closure: 8 process steps, 32 failure modes, actions with verification
• Quick_Start_Guide.pdf – 2 pages

Sheets: START_HERE · SETUP · PFMEA · DASHBOARD · PRINT · REVISIONS · FAQ · LICENSE

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HOW IT WORKS
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1. SETUP: header, scales, priority rules, process steps, owners
2. PFMEA: failure modes, effects, causes, controls – rate S, O, D
3. Actions: owner, due date, status – re-rate the target
4. Verify: effective Yes / No with evidence – only then the risk goes down
5. DASHBOARD and PRINT

Yellow cells are your input. Everything else is calculated and protected (no password).

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WHO IT'S FOR
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Quality and process engineers, quality managers, production managers, food safety / HACCP teams and suppliers asked for a PFMEA – plastics and packaging, automotive suppliers, food and beverage, metal parts, electronics, medical devices.

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IMPORTANT LIMITS – PLEASE READ
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• The priority comes from simple rules you control. They are NOT the AIAG-VDA Action Priority (AP) table – if your customer requires AP, adapt the rules or use the customer's tool.
• The file checks the PFMEA document, not whether your ratings are right: S, O and D are your team's judgement.
• Not included: DFMEA, the AIAG-VDA form, structure / function trees, automatic link to a control plan file.
• One part or process per file · 300 rows · 50 process steps · 20 owners · 40 revisions. No VBA / macros.

Related SmartFactoryTools templates: Control Plan Template, CAPA Tracker (Corrective & Preventive Action Log), Non-Conformance (NCR) Log & Cost Tracker.

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FAQ
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One failure mode with several causes?
One row per cause – repeat step, failure mode, effect and severity.

Why does the risk not go down when I enter new ratings?
New S / O / D are the target. The current risk only uses them when the action is Done, the completion date and action taken are filled, and the effect is verified with evidence.

Can I change the scales and rules?
Yes – descriptions, thresholds and the high-severity minimum are on SETUP.

Can I use it in Google Sheets?
No. It is built and tested for Microsoft Excel 2016 or newer on a computer.

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DIGITAL DOWNLOAD
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This is a digital product – nothing is shipped. After purchase, download the ZIP from Etsy (Purchases and reviews) on a computer, unzip it and open the BLANK or the EXAMPLE file in Excel.

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LICENSE
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For use in your own company or organization (any number of sites and users). Reselling, sharing or uploading the template elsewhere is not permitted. © SmartFactoryTools · SKU SFT-PFMEA-01