There are numerous ways (and acronyms) for dealing with parts and processing information.

I would not use a PFMEA alone to analyze a problem on an approved part during production unless the problem is one potentially caused by the processing itself.  A design FMEA would be useful as well.

If you have deviations to a part and run it through your processes, expect to have different results and potential problems.  Your processes cannot run "normally" when you intentionally introduce variation.  Hopefully you know the risks and costs beforehand to help make the choice on whether or not to use a discrepant component.

A PFMEA is not likely to be of help for immediate problems other than to illustrate and capture potential causes.  You would still need to look for the actual one(s).  Hopefully there are additional quality metrics in place that provide current data on how the processes are performing.

Regards,

Sounds like you're trying to do your supplier's job for him, yet, you're asking him to generate an 8D report, wherein, disciplines 5,6, and 7 relate to the correction of the problem.  If the problem persists, then, either the supplier's 8D was wrong, or he's not implementing his corrective actions.  

In either case, what would any analsis done by you have any bearing on the problem at hand?

TTFN

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