Course overview
DFMEA (Design Failure Mode and Effects Analysis) is a methodology for identifying, assessing, and prioritizing potential risks introduced in a new or changed design of a product. Once the risks have been identified, the organization will manage a plan to minimize or eliminate the impact of negative events on the product as designed.
This course meets in full the DFMEA requirements of AS13100:2021 (clauses 21.1 and 21.2) and the RM13004 document plus the Phase 2 requirements for DFMEAs included in AS9145 (clause 4.4.4.1 & 4.4.4.2).
In addition, this course also complies with the six-step process mandated in SAE – J1739:2021.
Both the RM13004 and J1739 ranking criteria for severity, occurrence and detection are included.
After completing this e-Learning course, participants will have learned from scratch how to understand and apply risk-based thinking and risk management to product design and be able to use DFMEA 'scoping tools’ including: B-O-M, Block/boundary diagram, Interface matrix and Parameter diagram.
A combination of quizzes, tests and personal assignments are used to ensure understanding of the principles and practices involved.
Included are downloadable ‘templates’ (in English) to provide the basis of customizable documents/spreadsheets for immediate use.
a downloadable (pdf) Delegate Workbook is included
The objective is to qualify practitioners who will be ‘subject experts’ able to lead cross-function teams to undertake effective DFMEA projects.
Course details
The course is delivered as an online e-Learning module via TEC's learning management system (LMS) platform. Within this e-Learning course, the following sections are covered:
Concepts of risk management & the FMEA process
Definition of risk management
Risk management standards
Test: risk management standards
Risk management strategies
FMEA process
Test: standards relating to DFMEA and/or PFMEA
FMEA philosophy
Test: purpose of the FMEA philosophy/process
Overview of the FMEA process
Purpose of the FMEA process
Types of FMEAs
Quiz: FMEA-related acronyms and terminology
The FMEA methodology
Generic FMEA Process Steps
Test: sequence of the generic FMEA Process Steps
Project planning
Determine the scope of the project
Quiz: product/scope related terminology
Perform preliminary risk assessment for Design FMEA
Personal assignment: customizing your own Preliminary Risk Assessment Matrix
Determine number and types of FMEAs needed for project
Prioritize Design FMEAs
Test: prioritization of Design FMEA
Develop DFMEA plan for project
DFMEA preparation
Determine the scope of the project
Bill of material (System Hierarchy)
Block/boundary diagram
Interface matrix
Parameter diagram (P-diagram)
Test: DFMEA ‘scoping’ tools
Assemble the FMEA Team
FMEA staffing considerations
FMEA owners
DFMEA team members and responsibilities (cross-functional teams)
FMEA project time
FMEA training and competency
Test: DFMEA owners, team members, and their competency
FMEA timeline in the PDP/APQP cycle
Timeliness of FMEAs
cheduling FMEAs in PDP/APQP cycle
Test: FMEA timeliness and timing in the PDP/APQP cycle
Cost savings and benefits of DFMEA
Cost reasons for early deployment of DFMEAs (and PFMEAs)
Benefits of DFMEAs
Quiz: identifying the benefits of DFMEAs
The design process
The DfX approach
Understanding the ‘Xs’
Concurrent engineering (DfMA)
Design for Manufacturing (DfM)
Design for Assembly (DfA)
Test: DFA, DFM and DFMA features and differences
FMEA concepts, data and terminology
Common FMEA concepts, sequence of activities and terminology
FMEA focus is on ‘potential’ problems
Test: FMEA concepts, data and terminology
Common FMEA terminology
DFMEAs and PFMEAs generic terminology
DFMEAs and PFMEAs generic rules
DFMEA worksheet template
Personal assignment: download DFMEA worksheet & customize
Sequence of the DFMEA steps/activities
Test: sequence of DFMEA steps/activities
DFMEA Linkages
DFMEA-specific terminology
1a Item
1b Function
1c Requirement
2 Failure Mode
Test: matching generic causes with examples
3 Effect
Test: identifying poorly-worded effects description
4 Severity [S]
Personal assignment: downloading the AESQ & SAE severity ranking criteria
Test: assigning severity ratings scores to severity categories
Classification (CIs, KCs & Special Requirements)
5 Cause
Test: identifying poorly-worded causes description
6 Current design controls
6a Occurrence [O]
Personal assignment: download the AESQ & SAE occurrence ranking criteria
Test: assigning occurrence ratings scores to occurrence categories
6b Detection [D]
Personal assignment: download the AESQ & SAE detection ranking criteria
Test: assigning detection ratings scores to detection categories
7 RPN
Test: calculating RPNs
Understanding RPN ‘thresholds’
Alternatives to basic RPN prioritization
Risk prioritization
Systematizing the action plan
Revision session & test of understanding
Consolidate your learning
Test: matching information to DFMEA elements
Deploying the action plan
Recommended actions
Focus on high [S] and critical items
Examples of actions
Test: identifying poorly-worded actions
Responsibility for actions
Summarizing the key findings
Rescoring the S, O, D – and the ‘new’ RPN
Post DFMEA activities
Design verification plan (DVP)
Requirements for DVP and Report
Design qualification/verification
DFMEA – PFMEA links
Quiz: DFMEA inputs & DFMEA-PFMEA links
Evaluating/auditing the DFMEA process
AESQ key questions
Personal assignment: creating a DFMEA audit checklist
Qualifications & benefits
The benefits of e-Learning (on-line training) are numerous; not only are they extremely cost-effective but they provide students with convenience and flexibility as they embark on their learning journey. Learners can complete their training whenever and wherever they want, and at their own pace.
Companies do not have to tie-up entire teams at the same time as is the case with conventional classroom-based training.