The Automotive Quality Management System of IATF16949:20016 required the organization to establish and maintain the PFMEA to support the implementation a risk based thinking for achieving effective quality management system and defect prevention. Even there are several guidelines to develop the PFMEA, there are inconsistency in development of FMEA and determining the elements in PFMEA. Hence PFMEA fail to deliver the intended results to prevent product defect origins from manufacturing process. This paper explores the common issues in FMEA through case study and proposed the countermeasure to develop an effective PFMEA through series of workshops. The output of this paper is guideline to develop effective PFMEA.