Planning & preparation
Define the study, team, scope, timing and source information.
LearnEX Digital · Zero Defect Pro
From process risk to zero-defect execution.
PFMEA should be a living prevention system—not a spreadsheet completed for the audit.
Zero Defect Pro connects AIAG-VDA’s seven steps, engineering logic, risk decisions, actions, evidence and operational outputs in one governed desktop workspace.
AIAG-VDA · Seven-step workspaceLocal-first · Human-governed
Connected failure logic
Every decision keeps its engineering context.
The failure chain stays connected from intended function through risk and action, making gaps easier to see and reviews easier to conduct.
01
Function
What the process step must deliver, with its requirements and characteristics.
02
Failure mode
How the function could fail to be delivered as intended.
03
Effect
The consequence for your plant, the ship-to plant and the end user.
04
Cause
Why it can happen, traced to a work element: man, machine, material or environment.
05
Controls
Current prevention and detection controls against the cause and the failure mode.
06
Risk & action
Severity, occurrence and detection set the action priority; actions close the gap.
AIAG-VDA workflow
Seven steps. One connected source of truth.
The workspace mirrors the method so planning, analysis, optimization and results do not fragment across files and handoffs.
Structure analysis
Model the process, process steps and work elements as a navigable system.
Function analysis
Connect functions, requirements and characteristics to the structure.
Failure analysis
Expose failure modes, effects and causes as a traceable failure chain.
Risk analysis
Evaluate severity, occurrence, detection and action priority with context.
Optimization
Assign prevention and detection actions with owners, evidence and due dates.
Results documentation
Produce governed reports, control-plan outputs and a reusable knowledge trail.
Inside the system
A living FMEA from preparation to learning.
Planning, characteristics, structure, functions, failures, risk and optimization stay linked in one connected workspace instead of drifting across files.
01
Failure logic teams can inspect
A causal matrix makes the relationship between work elements, causes and failure modes easier to review across functions.
02
Risk translated into action
Severity, occurrence and detection roll up into action priority for every failure mode and cause, with the evidence beside it.
03
Optimization with accountability
Prevention and detection actions retain owners, rationale, status and verification in the same system.
Enterprise controls
Designed for governed deployment.
Governed AI
Suggestions remain visible and reviewable; every one is accepted, edited or rejected by a person.
Local-first data
A local SQLite database supports day-to-day offline work, with configurable backups under enterprise control.
Role-aware workflow
Administrator, analyst, approver and viewer roles, with independent shop workspaces and cross-shop comparison.
Operational continuity
Revision history, PDF FMEA reports and AIAG-VDA control-plan export keep the FMEA connected to execution.
Focused pilot
One part. One critical process. One cross-functional team.
A four-to-six week pilot lets the team evaluate the workflow on a real prevention challenge without starting with an enterprise-wide rollout.
- 01
90-minute discovery
Agree the part, the critical process and what the pilot needs to show.
- 02
Focused configuration
Set up the workspace, roles and reference data for that one process.
- 03
Team pilot and review
The cross-functional team works the PFMEA, then reviews the results together.
Product FAQ
Questions enterprise teams ask early.
Does Zero Defect Pro replace engineering judgement?+
No. It structures the work, connects the evidence and can suggest options; the cross-functional team remains responsible for every engineering decision.
Where does the data live?+
The desktop application uses a local SQLite database. Normal day-to-day work can continue offline, with internet access used periodically for licensing and any configured cloud AI provider.
Can different plants work independently?+
Yes. Shop workspaces isolate operational FMEA data while shared reference data and comparison views support enterprise governance.
How is AI governed?+
Suggestions remain reviewable. Users can accept, edit or reject them, and the workflow retains the human decision rather than silently changing the FMEA.
What does a focused pilot look like?+
A typical pilot centers on one part, one critical process and one cross-functional team over four to six weeks, beginning with a 90-minute discovery workshop.
See it with your process in mind
