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
02
Failure mode
03
Effect
04
Cause
05
Controls
06
Risk & action
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.
01
One connected workspace
Planning, characteristics, structure, functions, failures, risk and optimization stay linked instead of drifting across files.
02
Failure logic teams can inspect
Visual chains make the relationship between effects, modes, causes and controls easier to review across functions.
03
Risk translated into action
Priorities move into owned actions, Kanban workflow, deadlines and evidence rather than remaining a static score.
04
Optimization with accountability
Prevention and detection actions retain owners, rationale, status and verification in the same system.
05
Analytics for the living FMEA
Risk heatmaps, anomalies, action status and health indicators reveal where the system needs attention.
06
Revision and learning history
Revision comparison, 8D linkage and a risk time machine keep decisions and changes reviewable.
Governed AI
Suggestions remain visible, reviewable and subject to human acceptance, editing or rejection.
Local-first data
A local SQLite database supports day-to-day offline work and enterprise-controlled backups.
Role-aware workflow
Administrator, analyst, approver and viewer roles support structured participation.
Operational continuity
Revisions, exports, actions and control-plan outputs keep the FMEA connected to execution.
Enterprise controls
Designed for governed deployment.
01Local SQLite data with day-to-day offline operation
02Independent shop workspaces with cross-shop comparison
03Administrator, analyst, approver and viewer roles
04Configurable backups and revision history
05PDF FMEA reports and AIAG-VDA control-plan export
06Governed AI suggestions with accept, edit and reject decisions
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
- 02
Focused configuration
- 03
Team pilot and review
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