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New part launch: build the PFMEA before the Control Plan

A new part or process is launching and the PPAP is due.

By Chris Martin, quality manager. Last updated October 6, 2026.

For a new part launch, build the PFMEA first so the risks drive the controls, turn it into a Control Plan, prove your gages with a Gage R&R, measure first articles against every drawing characteristic, and assemble the PPAP submission at the level your customer requires.

Start with

Start the PFMEA before the Control Plan, not after.

The path, in order

  1. PFMEA

    Walk the process flow step by step. For each step, list how it can fail, the effect and the cause. Rate the risks and decide actions while the process can still change.

  2. Control Plan

    For each product and process characteristic, set the specification, measurement method, sample size and frequency, control method and reaction plan, drawing on the PFMEA.

  3. Gage R&R

    Confirm every gage used on key characteristics can tell good parts from bad before you trust its readings.

  4. FAI

    Measure parts from the production process against every characteristic on the drawing and record the results.

  5. PPAP

    Assemble the elements your customer requires at the submission level they specify, with the Part Submission Warrant.