PURPOSE OF DFMEA (DESIGN FAILURE MODE EFFECTS ANALYSIS

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• Identify, quantify, and reduce design risk (especially for critical systems) • Provide a traceable document for making design decisions • Prioritize which design activities to pursue next • NOTE: A DFMEA is not a one meeting activity (It needs to evolve with the product)

DFMEA INPUTS • Product Design Requirements – Design requirement document (if available from customer) – Legal and technical regulations • Bill of Materials (BOM) and Specific Hardware – List of components – Components and/or samples as supplied by the customer • Product Definition – Drawings. and simulations – Description of systems and components • Previous Experience (Lessons Learned from Others) – Experience with similar concepts. and DFMEA – Customer and supplier inputs – Design guides and design standards (for example ASME codes) . animations. sketches. designs.

• Identification of Critical and Significant Characteristics (This is also normally required by a customer) .DFMEA OUTPUTS • RAN: Risk Assessment Number – RAN = (Severity) x (Occurrence) x (Detection) – Identification of both systems and components with high RAN values represents a summary of high risk items.

) Complete the top of the form – Project. then subsystems.) Document the potential effects of failure – How would the design potentially fail to meet the design intent. team members. component to subsystem) or the effect of a failure at a lower level.DFMEA METHODOLOGY • (1. date. and DFMEA iteration • (2.) List items and functions – Start with the system.e. year. . and finally components • (3.) Document potential failure modes – How could the design potentially fail to meet the design intent – Note: this might be the cause of failure at a higher level (i. – Consider all types of failure • (4.

but repair is possible 4 = device damaged beyond repair 5 = failure causes moderate to severe operator injury • (6.) Document potential causes and mechanisms of failure – – – – Failure causes and mechanisms are an indication of design weaknesses Potential failure modes are the consequences of the failure causes A single failure mode may have multiple failure mechanisms Don’t be afraid to identify as many potential causes as you can .DFMEA METHODOLOGY: (CONTINUED) • (5.) Rate the severity of the failure effect (linked to the effect of the failure) 1 = device operable with minor loss of functionality 2 = device operable with significant loss of functionality 3 = device damaged and inoperable.

limit tests) Proven designs. and materials . simulation.) Rate the occurrence of the failure 1 = likely to occur at some point in product testing 2 = likely to occur periodically across multiple test sessions 3 = likely to occur during almost every test session • (8. parts. and modeling Tolerance “stack-up” studies Prototype test results (acceptance tests. DOE’s.DFMEA METHODOLOGY: (CONTINUED) • (7.) List the design controls – Design controls are intended to: • Prevent the cause of the failure mode (1st choice solution) • Detect the cause of the failure mode (2nd choice solution) • Detect the failure mode directly (3rd choice solution) – Applicable design controls include • • • • Predictive code analysis.

) Calculate the RAN of each potential failure effect – RAN = (Severity) x (Occurrence) x (Detection) – What are the highest RAN items? • (11.) Define recommended actions – These could be design changes.DFMEA METHODOLOGY: (CONTINUED) • (9. tests. or revised operation procedures .) Rate the detectability of the failure 1 = uses sensors and active controls to avoid upset condition 2 = uses operator training/procedures to spot imminent failure 3 = fails without warning • (10.

a new detection method. better codes) • (14.) Assign action items • (13.) Repeat: undertake the next revision of the DFMEA Revise your DFMEA frequently! Include documentation of your results! . but the rules are: • Severity: May only be reduced through elimination of the failure effect • Occurrence: May only be reduced through a design change • Detection: My only be reduced through improvement and additions in design control (i.DFMEA METHODOLOGY: (CONTINUED) • (12.) Complete “Action Results” Section of DFMEA – Change ratings if action results justify adjustment.e. better test methodology.