The growing demand for flexible, sustainable, and individualized production is giving rise to complex manufacturing systems and comes along with a higher susceptibility to process-related disruptions. Due to the costs associated with disruptions, effective disruption management is increasingly becoming a decisive factor in maintaining and expanding a company’s competitiveness. The formalization of disruption situations and their effects is a prerequisite for adapting short-term compensation strategies within the process chains as well as the basis for the long-term resilient design of manufacturing systems. This paper introduces a 3-phase approach whose application enables a complete modeling and analysis of process-related disruptions in manufacturing systems. In phase 1, the disruption scenario is modeled by classifying it based on known variables and forecasting uncertain disruption characteristics. Phase 2 analyzes the capacitive effects along the process chain using a simulation model. In phase 3, the technological effects of the disrupted process step on the condition of the workpiece are determined.