A free check that compares PFMEA risks with Control Plan controls. Enter each risk, its severity and detection ratings, and the control listed in the Control Plan. The check flags risks with no control and severity 9 or 10 risks that rely on weak detection.
Nothing you type leaves your browser. Clearing or closing the page removes it.
What it checks
| Result | When it shows | What to do |
|---|---|---|
| No control | The Control Plan column is blank for a risk. | Add a control with a reaction plan, or record why none is needed. |
| Weak for severity | Severity is 9 or 10 and the detection rating is 7 or higher. | Look at error-proofing or a stronger detection method. |
| Covered | A control is listed and the case above does not apply. | Confirm the control and reaction plan are actually in use on the floor. |
| Needs rating | No valid severity from 1 to 10 was entered. | Rate the risk in the PFMEA first. |
Worked example
Three risks from a machined part: a burr on the bore edge (severity 5, covered by 100% visual at final inspection), dimension 14 out of tolerance (severity 7, no control listed), and a wrong material lot (severity 9, covered only by a receiving certificate review rated 8 for detection).
The check returns one Covered, one No control for dimension 14, and one Weak for severity for the material lot, because a severity 9 risk relies on a control rated 8 for detection.
Why this gap matters
The PFMEA says what can go wrong. The Control Plan says how the process is controlled day to day. When a risk sits in the PFMEA with no matching control, nothing on the floor is watching for it, and that is a common place for escapes and audit findings to start. Read more in Control Plan vs PFMEA.
Severity and detection follow the scales in your own PFMEA. In both the AIAG and AIAG-VDA approaches, severity 9 and 10 cover safety and regulatory effects, and a higher detection number means weaker detection. This is a screening check, not a replacement for a PFMEA review.