Zhijian FMEA Product Introduction

01 Product Introduction

Zhijian FMEA is not a simple FMEA document editing tool, but a complete digital solution for manufacturing quality risk. It effectively resolves business pain points of traditional Excel-based FMEA: chaotic version control, low multi-party collaboration efficiency, difficult experience reuse and accumulation, non-standard analysis processes, and fragmented/disconnected data between multiple documents. It supports local deployment and AI intelligent assistance, connecting the full business closed-loop of FMEA analysis, collaborative review, knowledge accumulation, and result output.

Product Overview

Product Positioning

Zhijian FMEA is not a simple FMEA document editing tool, but a complete digital solution for manufacturing quality risk. It effectively resolves business pain points of traditional Excel-based FMEA: chaotic version control, low multi-party collaboration efficiency, difficult experience reuse and accumulation, non-standard analysis processes, and fragmented/disconnected data between multiple documents. It supports local deployment and AI intelligent assistance, connecting the full business closed-loop of FMEA analysis, collaborative review, knowledge accumulation, and result output.

Core Value

1. Standardized analysis — compliant with the new AIAG-VDA PFMEA seven-step method standard
2. Digital transformation — say goodbye to Excel spreadsheets, realize FMEA online collaborative analysis
3. Knowledge accumulation — digital accumulation and reuse of enterprise FMEA experience
4. Quality traceability — full-process records, supports quality event traceability

Pain Point 1: Unable to grasp business status in real time and globally

Traditional Mode Dilemma: Information lag, passive decision-making. Relying on regular reports, unable to grasp the global status in real time, there is an inherent delay in information transmission, making it difficult for management to conduct timely and effective review and business guidance, and risk control is in a passive response state.

Zhijian FMEA: Digital Global Control Solution

• Panoramic dashboard, real-time insight: Provides a global view, real-time display of project count, progress, risk level distribution, and measure closure rate; key indicators visualized, allowing management to grasp first-hand dynamics at any time.
• Online review, efficient collaboration: Breaks time and space limits, supports online comments, approval and return; management can directly intervene in project guidance, greatly improving review efficiency and achieving real-time closed-loop business guidance.
• Intelligent alerts, decision support: High-risk items automatically trigger alerts, supports one-click export of multi-dimensional enterprise-level summary reports, providing management with accurate data support for scientific decision-making and risk control.

Pain Point 2: Poor analysis results affect product quality

Traditional Mode Limitations: Traditional FMEA analysis heavily relies on manual experience and lacks unified standards, leading to uneven analysis results. Potential risks are difficult to comprehensively identify and effectively control, not only affecting product quality stability, but also potentially causing after-sales hazards and damaging brand reputation and market competitiveness.

Zhijian FMEA: Standardized analysis process, front-loaded quality risk control

• Standardized analysis engine, eliminates human omissions: Strictly follows the AIAG-VDA seven-step method standard, built-in mandatory standardized process and logic verification, reducing manual missed/misjudgments, ensuring standardized analysis process and traceable results, and guaranteeing analysis quality from the source.
• Centralized risk control, closed-loop rectification without blind spots: Real-time highlight alerts for high-risk failure modes, establishes a closed-loop tracking mechanism for rectification measures; projects without completed rectification cannot enter the next stage, ensuring thorough resolution of risk issues.
• Linked historical quality issue library, avoids duplicate risks: Built-in historical quality issue database, automatically links similar failure cases during analysis, identifies and avoids recurring issues in advance, achieving front-loaded quality risk control and significantly improving product reliability.

Pain Point 3: Historical data scattered and easily lost

Traditional Mode Dilemma: Historical data is scattered in local documents, different computers or offline devices, lacking a unified management system. It is not only highly susceptible to permanent data loss due to equipment damage or personnel changes, but also difficult to quickly retrieve and reuse, causing hidden loss of valuable enterprise knowledge assets and duplicate work.

Zhijian FMEA: Unified data control, secure and complete

• Unified centralized storage: Builds an enterprise-level FMEA knowledge base, all projects are uniformly archived in the cloud, saying goodbye to local scattering and file loss risks, achieving secure retention and centralized management of data assets.
• Multi-dimensional intelligent retrieval: Supports precise retrieval by product model, parts, processes, failure modes and other dimensions, quickly retrieves historical experience, avoids duplicate analysis, and greatly improves R&D efficiency.
• Full-process version traceability: The system automatically retains every change record, forming a complete version chain that can trace back historical modification processes at any time, ensuring documents are traceable, data is not lost, and compliance requirements are met.

Pain Point 4: Experience cannot be passed on

Traditional Mode: Experience silos, asset loss: Over-reliance on individual expert experience, knowledge is scattered and difficult to accumulate; once personnel leave, core experience is lost, unable to be transformed into long-term enterprise assets, leading to reinventing the wheel and seriously restricting the efficiency and depth of quality analysis.

Function Library | Failure Library | Measure Library | Characteristic Library | Issue Library

Zhijian FMEA: Build an enterprise-level quality knowledge base

• Automatic accumulation: Builds a standardized knowledge base; analysis results such as failure modes, root causes, and control measures are automatically entered into the library, forming a structured, retrievable enterprise quality knowledge base, saying goodbye to fragmented experience.
• Global sharing: Experience reuse improves efficiency; cross-department and cross-project teams directly call historical mature experience, avoiding duplicate analysis, shortening project cycles, while ensuring consistency of analysis quality.
• Asset solidification: Personnel flow does not lose experience; individual experience is transformed into permanent enterprise assets, not lost due to employee departure, continuously providing stable intellectual support for the enterprise quality system.

Software Benefit Analysis: Dual improvement of efficiency and quality

Significant improvement in man-hour efficiency

• New project efficiency improved 30%-40%: Automatic report generation, version management and multi-person collaboration greatly reduce duplicate labor.
• Modified project improved 60%-80%: Heavy reuse of historical FMEA data, only differences need modification, documents auto-link and update.
• Cycle greatly shortened: Traditional Excel takes 5 days, mature library only 1-2 days.

Comprehensive process quality assurance

• Failure missed identification rate ↓40%-60%: Based on failure network and historical defect library for assisted identification, risks have no blind spots.
• Human error ↓70%+: Built-in scoring standard references, change one place, multiple places sync, eliminating inconsistency.
• Batch defect rate ↓20%-40%: Control risks from the source, effectively reducing quality losses of new product production.

Knowledge accumulation and collaboration efficiency

• Release core manpower value: Reduce tedious document writing, focus on process optimization and on-site problem improvement.
• Audit efficiency improved 30%-50%: Standardized documents reduce audit difficulty, calmly handle customer audits.
• Enterprise knowledge asset accumulation: Experience and cases stored in the system, avoiding experience gaps caused by personnel loss.

02 Product Highlights

"Zhijian FMEA" is built on a self-developed platform and integrated with AI large models, realizing full-process visual analysis, FMEA and knowledge base linkage, five AI one-click intelligent capabilities, and can integrate with enterprise internal systems to eliminate information silos.

2.1 Visualization — Three Trees, Two Networks, One Diagram, more complete risk identification

The system relies on the three trees, two networks, one diagram full-dimensional visualization architecture to reconstruct FMEA risk identification logic, breaking the traditional single-point, fragmented analysis approach, achieving systematic, structured, full-coverage identification of product and process risks.

2.2 Data Linkage — Knowledge base + Basic/Family/Product, greatly shorten preparation man-hours

Three-layer linkage:

Basic FMEA → Family FMEA → Product FMEA

Basic→Family→Product inherit layer by layer, no need to repeatedly sort structure/processes, failures, control measures, greatly improving FMEA writing efficiency.

• Experience solidification and accumulation, unified standards
• Linked change synchronization, eliminates version chaos
• Rapid differentiated iteration
• Cost reduction, efficiency improvement, compliance and traceability

Knowledge base linkage:

Function Library | Failure Library | Measure Library | Characteristic Library | Issue Library

The system has built-in parts library, function library, characteristic library, failure library, measure library and other knowledge bases, accumulating mature enterprise process and quality experience, supporting multi-level FMEA data reuse for basic, family, and product. After knowledge base updates, linked project data can be synchronously changed, unifying analysis standards, avoiding manual entry deviations, greatly simplifying the preparation process, and effectively improving FMEA preparation efficiency and analysis standardization.

2.3 Five "AI One-Click" Functions

The system is equipped with an AI intelligent analysis engine, relying on standard knowledge bases such as functions, characteristics, failures, and measures, integrating five AI one-click intelligent capabilities, replacing traditional manual writing, verification, and analysis modes. Fully aligned with the new AIAG-VDA standard, intelligently completes content, automatically generates process and failure chains, standardized scoring, and intelligent file review, greatly improving FMEA preparation efficiency and analysis standardization.

2.4 Open interfaces, supports integration with existing enterprise information systems

1. ERP system integration: Realizes basic data synchronization, controls quality risks at the source, ensuring consistency and accuracy of production data.
2. MES system integration: Dynamically updates risk points, realizes real-time production process alerts, immediate anomaly response, ensuring smooth production.
3. QMS system integration: Builds quality closed-loop, continuously optimizes risk models, achieving full-process control from problem discovery to resolution.
4. PLM/PDM system integration: Front-loaded risk control, identifies potential hazards during product design, ensuring new product mass production quality and stability.
5. OA and other auxiliary systems integration: Connects approval processes, achieves upstream/downstream collaborative control, improving cross-department collaboration efficiency and information flow speed.

03 Function Introduction

FMEA core functions — seven-step method: Planning & Preparation, Structure Analysis, Function Analysis, Failure Analysis, Risk Analysis, Optimization Analysis, Result Documentation

Function Architecture

3.1 PFMEA: Step 1 Planning and Preparation

Supports standardized maintenance of basic data throughout the PFMEA project, including project name, product model, production process, applicable production line, project version, analysis phase, customer standards and industry specifications.

• Basic information maintenance
• Project plan
• Team management
• Preliminary input data: Import process BOM, process flow charts, define analysis scope, collect process materials, unify analysis baseline.

3.2 PFMEA: Step 2 Structure Analysis

New PFMEA three-level structure decomposition: Process Item (process) → Process Step (work step) → Process Element (6M: Man/Machine/Material/Environment/Method/Measurement)

According to the new AIAG-VDA PFMEA standard, the system completes three-level refined decomposition of process items, process steps, and process elements in the structure analysis phase. This is the core logic of standardized process FMEA analysis, completely replacing the traditional rough process sorting mode, achieving layer-by-layer penetration of the process from overall to detail, providing core support for precise identification of subtle risks and refined control granularity.

3.3 PFMEA: Step 3 Function Analysis

Following structure analysis, builds a three-level hierarchical function system of process item functions, process step functions, process element functions, product/process characteristics.

Outputs:

1. Visual function network: Automatically generates function network, intuitively displays function transfer and upstream/downstream linkage between processes and elements, achieving visual traceability of function chains.
2. Standardized function list: Automatically summarizes and generates function lists, solidifies standard functions of all processes and work elements one by one, forming a reusable, verifiable function baseline library.
3. Refined characteristic list: Based on function decomposition at all levels, organizes and outputs characteristic lists, precisely matching product and process core characteristic parameters, providing precise basis for failure identification and risk determination.

3.4 PFMEA: Step 4 Failure Analysis

Three-level failure architecture: Failure Effect FE → Failure Mode FM → Failure Cause FC

Core capabilities:

1. Standardized three-level failure architecture, strictly follows the new AIAG-VDA specification, FE→FM→FC associated level by level, building a logically closed-loop failure analysis system.
2. Complete failure chain closed-loop: Establishes a complete transmission chain of "standard function → function failure → failure mode → root cause", with clear risk traceability.
3. Precise hierarchical association matching: Process item, process step, process element failures correspond one-to-one, solving traditional FMEA function failure misalignment.
4. Knowledge base intelligent reuse: Links historical quality failure case library, automatically matches similar failure modes and root causes.
5. Says goodbye to pure empirical subjective judgment, achieving standardized full-coverage risk identification.

Outputs:

1. Automatically generated failure network diagram: Based on FE-FM-FC association relationships, automatically constructs visual failure network, intuitively displays failure transmission, association coupling, chain risks, achieving hidden risk visualization and traceability.
2. Standardized failure list output: One-click summarizes full-dimensional failure information, uniformly outputs standardized failure lists, covering all failure deviations, failure manifestations, underlying causes, forming a standardized failure baseline ledger, reusable, auditable, and traceable.

3.5 PFMEA: Step 5 Risk Analysis

1. SOD three-dimensional scoring system: Benchmarks the new PFMEA scoring criteria, standardized rating of Severity (S), Occurrence (O), Detection (D), eliminating arbitrary manual scoring.
2. AP Action Priority determination: Abandons traditional RPN, SOD matrix automatically determines AP (High/Medium/Low), defining rectification priority.
3. Preventive Measures & Detection Measures
   • Preventive measures: Reduce failure probability at the source (process, check, incoming material control).
   • Detection measures: After failure occurs, identify and intercept defects before outflow.

Matrix Analysis Distribution Diagram

Based on the new PFMEA scoring rules, the system breaks through the limitations of traditional single RPN analysis, constructing multi-dimensional matrix analysis distribution diagrams for S single-item, SO Severity-Occurrence, SD Severity-Detection, OD Occurrence-Detection, and AP Action Priority. Through visual matrix charts, it intuitively presents risk distribution, risk clustering intervals, and level differences in each dimension, achieving upgrade of risk from single scoring data to visual matrix distribution analysis, precisely identifying high-risk clustering areas, and providing visual data support for risk research, rectification resource allocation, and audit traceability.

• New multi-dimensional matrix system: Adapts to new AIAG-VDA standard, covers S, SO, SD, OD, AP full-dimensional matrices, replacing traditional single risk assessment mode with more comprehensive analysis dimensions.
• Risk visual distribution: Distribution diagrams and matrix heatmaps intuitively present risk clustering intervals; hidden and high-risk risks are clear at a glance.
• Precise control short-board positioning: Through multi-matrix cross-analysis, precisely identifies various risk shortboards such as high-frequency failures, high-risk failures, difficult-to-detect failures, targeting optimization of preventive and detection control measures.
• Risk grading visualization implementation: AP matrix links multi-dimensional data, achieving visual risk priority assessment, rationally allocating rectification resources, and improving risk governance efficiency.

3.6 PFMEA: Step 6 Optimization Analysis

• SOD values carry forward, one-click reuse of historical project and similar failure scores, ensuring unified process evaluation standards.
• Automatically generates optimization rectification tasks for high-AP risk items, pushes messages to responsible persons, overdue reminders and supervision.
• Edit optimization measure forms, record responsible person, target completion time, rectification evidence, actual completion time.
• Rectification closed-loop: Rectification completion automatically writes back SOD values, updates matrix heatmap, achieving "risk identification → task → rectification → update" complete closed-loop.

3.7 PFMEA: Step 7 Result Documentation

Supports exporting new AIAG-VDA PFMEA standard documents, old AIAG FMEA format, Control Plan CP files, supports Word/Excel output, for customer audits and IATF16949 system archiving.

Control Plan Makes PFMEA risks no longer stay at the analysis level, automatically transforms them into mass production site standard control basis, achieving full closed-loop from risk analysis to quality implementation

04 Deployment & Implementation

From local servers to cloud environments, we provide secure and stable environment deployment and operation services, so you don't need to worry about the underlying architecture and can focus on business growth.

4.1 Deployment Method

SaaS Edition

• Ready to use upon tenant activation
• No server operation and maintenance costs
• Flexible use
• Low cost

Private Edition

Private deployment, 100% self-controlled data; open API and standard interfaces, supporting deep integration and custom development.

Configuration Requirements

4.2 Technical Support

Making Software Smarter · Making Operations Simpler

Beijing Shuke Zhijian Technology Co., Ltd.