Failure Process Matrix (FPM)

Do you know your failure costs? Do you have difficulties using methods to minimize risks associated with assembly processes?

The generally-accepted aim of zero-failure production is rarely achievable due to the high costs of pinpointing and eliminating errors. The established method of error prevention in production processes - failure mode and effects analysis (FMEA) - is of little or no help when it comes to evaluating the cost-effectiveness of the measures for assembly processes defined by FMEA.

Fraunhofer IPA has developed a Failure Process Matrix (FPM). Complex assembly processes are correlated with potential errors in a matrix in a straightforward manner. Together with production figures as well as costs related to rejects and rework, sound information is gained as early on as in the planning phase about anticipated failure costs and the productivity of assembly processes. On the basis of these results, assembly processes are then optimized from a general economic perspective according to the criteria of quality, costs and productivity.


  • Optimization of control concepts for assembly processes using FPM,
  • Seminars on FPM, implementation of FPM in companies as well as coaching for FPM moderators,
  • Use of FMEA controlling to integrate potential causes of supply-related errors into the overall optimization of inspection planning with FPM,
  • Training courses on the use of tools to support FPM as well as assistance with their implementation,
  • Support in using WebFPM, the tool for the central storage and analysis of FPM data.