Projects, not just calculations.

PFMEA (AIAG-VDA)

Build a process FMEA as a structure: process item, steps, work elements and their functions, with failure chains from effect to mode to cause. Rate severity, occurrence and detection, plan actions and re-rate them after.

• Structure tree with work elements (4M) and characteristics
• Failure chains with S / O / D ratings and action priority (AP)
• Actions with re-rating, revisions and a change log
• Excel export and import, A3 print

The action priority table is marked unverified: check it against the handbook before relying on it.

Control plan

The control plan reads the characteristics of your PFMEA and builds its rows from them. When the PFMEA changes, the plan shows what is out of sync and brings it up to date in one click, without touching rows you added yourself.

• Rows from PFMEA product and process characteristics
• Out-of-sync check with one-click synchronisation
• Three phases, each with its own control columns
• Excel export and import, A3 print

8D report

Work one problem through the eight disciplines, from the team and the problem description to the verified root cause, the corrective actions and the closure. The Ishikawa diagram and the 5 Why are part of the report, and action tracking shows what is overdue.

• D0–D8 with status and date, team, 5W2H and is / is not
• Ishikawa diagram you edit and export, and 5 Why
• Action tracking with owners, dates and effectiveness
• Proposals for the PFMEA, applied only when you confirm

The structure is general practice, not a normative standard.

Dimensional report (PPAP / AS9102)

List the characteristics from your PFMEA with tolerances, balloon numbers and measured samples. Results are compared exactly in decimal arithmetic, and the report is written in the AS9102 Form 3 and PPAP dimensional results layouts.

• Characteristics from the PFMEA, kept in sync
• Plus / minus, limits or text requirements, 1–30 samples
• Exact decimal comparison of results against limits
• Excel export and A4 / A3 print

The form layouts are marked unverified: compare them with the form you must submit.

Value stream map (VSM)

Map one product family from the supplier to the customer: the processes with their data, the stock between them, push, FIFO and supermarket links and the information flow. The timeline adds up lead time, value-added time and PCE, and the future state carries the kaizen bursts that get you there.

• Processes, stock, push / FIFO / supermarket and information flow
• Takt, lead time, value-added time, PCE and the bottleneck
• Future state as a copy, with kaizen bursts
• Excel with formulas, SVG, PNG and A3 print

The symbols are drawn in a simplified style and marked unverified; lean mapping is common practice, not a standard.

A3 report

Work one problem through plan, do, check, act on a single sheet: background, current condition and goal on the left, countermeasures, plan and follow-up on the right. The Ishikawa diagram and the 5 Why are the same editors as in the 8D report.

• Background, current condition and a goal with one metric
• Ishikawa diagram and 5 Why, root cause
• Countermeasures and plan with owners and dates
• Run chart with gap closed, A3 print, Word and Excel

The A3 layout is common practice, not a standard.

5S audit

Audit an area against your own 5S questions and see each S as a share of the points possible, on a radar and as a trend from audit to audit. The audits, the questions and the actions are one project with the layered process audit.

• Questions per S, editable, scored 0–4 or 0–5
• Share per S and in total, radar and trend
• Actions with owner, due date and status
• Excel with formulas, Word, print and a blank sheet

The questions are FactoKit’s example wording, not an official checklist.

Layered process audit (LPA)

Every layer, from team leader to plant manager, audits the same process at its own rhythm with short yes / no questions. Compliance per audit, the missing countermeasures and a completion matrix show whether the layers keep it up.

• Layers with daily, weekly or monthly frequency
• Questions per layer, yes / no / N/A
• Countermeasure required for every “no”
• Completion matrix, Excel, Word, print and a blank sheet

The questions are FactoKit’s example wording, not an official checklist.