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 ‘face-to-face’ course and workshop meets in full the DFMEA requirements of AS13100:2021, J1739:2021, RM13004:2021 and AIAG & VDA:2019 plus the Phase 2 requirements for DFMEAs included in AS9145:2016 (clause 4.4.4).
The RM13004, AIAG & VDA and J1739 rating criteria for severity, occurrence and detection are addressed.
Design for ‘X’ (DfX) and identification of KCs and CIs are included.
After completing this ‘face-to-face’ 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, Parameter diagram and Structure & Function Analysis.
A combination of individual/team quizzes, tests and assignments are used to ensure understanding of the principles and practices involved.
Course details
This ‘face-to-face’ course and workshop is delivered over 2 consecutive days with continual assessment and feedback provided by the tutor(s).
The following topics 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
Overview of the DFMEA methodology
DFMEA analysis, focus and sequential steps
Current manual/handbook/standard relating to FMEAs
Generic FMEA Process ‘Steps’
J1739 and AIAG & VDA ‘steps’ comparison
Test: sequence of the generic FMEA Process Steps
Assemble the FMEA Team
FMEA staffing considerations
FMEA owners
DFMEA team members and responsibilities
FMEA project time
Baseline/Generic DFMEA
FMEA training and competency
Test: DFMEA owners, team members, and their competency
Project planning conciderations
Determine the scope of the project
Quiz: product/scope related terminology
Perform preliminary risk assessment for Design FMEA
Workshop: your typical ‘cases’ of product change/risk
Determine number and types of FMEAs needed for project
Prioritize Design FMEAs
Test: prioritization of Design FMEA
Develop DFMEA plan for project
DFMEA project planning guidelines (Five T’s)
DFMEA preparation
Determine the scope of the project
Block/boundary diagram
Workshop: your example of a Block/Boundary diagram
Interface matrix
Bill of Material (B-O-M) and System Structure
Workshop: B-O-M and System Structure
Understanding structure analysis
Workshop: structure analysis
Parameter diagram (P-diagram)
Characteristics of P-Diagrams
Workshop: your example of a P-Diagram
Understanding function analysis
Workshop: function analysis
Structure Analysis ~ Function Analysis
Example: Structure Analysis and Function Analysis alignment
Test: DFMEA ‘scoping’ and ‘function’ tools
FMEA project plan and timeline in the PDP/APQP cycle
Finalize the FMEA project plan
Timeliness of (all) FMEAs
Scheduling FMEAs in PDP/APQP cycle
Test: FMEA timeliness and timing in the PDP/APQP cycle
The Design-for-X process
The DfX approach
Understanding the ‘Xs’
Concurrent engineering (DfMA)
Design for Manufacturing (DfM)
Design for Assembly (DfA)
DfMA is a 'combination' of DfM and DfA
Test: DFA, DFM and DFMA features and differences
Overview of FMEA data, DFMEA analysis process and rating
Common FMEA data and information
DFMEA focus and risk analysis process
DFMEA (S), (O) & (D) rating terminology
Test: FMEA concepts, data and terminology
Common FMEA terminology, project rules & the DFMEA worksheet
DFMEAs (and PFMEAs) generic terminology
DFMEAs (and PFMEAs) generic rules
DFMEA worksheet template
Workshop: your DFMEA worksheet
Sequence of the DFMEA steps/activities
Test: sequence of DFMEA steps/activities
DFMEA Linkages
DFMEA-specific terminology
1a Item
1b Function
1c Requirement
Workshop: relating function and requirement to an item
2 Failure Mode
Test: matching generic causes with examples
Workshop: identifying failure modes
3 Effect
Test: identifying poorly-worded effects description
Workshop: identifying failure effects
4 Severity (S)
AESQ & SAE severity rating criteria
Automotive (AIAG & VDA) severity rating criteria
Test: assigning severity ratings scores to severity categories
Workshop: assigning severity rating score
Classification (CIs, KCs & Special Requirements)
5 Cause
Test: identifying poorly-worded causes description
_Workshop: identifying the cause(s) of failure modes
6 Current design controls
6a Occurrence (O)
AESQ & SAE occurrence rating criteria
Automotive detection rating criteria
Test: assigning occurrence ratings scores to occurrence categories
_Workshop: assigning Occurrence and Detection ratings
6b Detection (D)
AESQ & SAE detection ranking criteria
Automotive detection rating criteria
Test: assigning detection ratings scores to detection categories
Workshop: assigning Occurrence and Detection ratings
7 RPN
Test: calculating RPNs
Understanding RPN ‘thresholds’
Alternatives to basic RPN prioritization
Test: prioritizing sequence for action using “S~O~D” values
Workshop: determining measures of action prioritization
Automotive Action Priority (AP)
Risk prioritization – for action
Systematizing the action plan
Developing recommended actions
Workshop: developing required actions
The action plan recorded on the DFMEA worksheet
Revision session & test of understanding
Consolidate your learning
Test: matching information to DFMEA elements
Deploying the action plan
Recommended actions
Improvement strategies
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 (R)
Design qualification/verification
DFMEA – PFMEA links
Quiz: DFMEA inputs & DFMEA-PFMEA links
Evaluating/auditing the DFMEA process
AESQ key questions
Cost savings and benefits of DFMEA
Cost reasons for early deployment of DFMEAs (and PFMEAs)
Cost benefits of DFMEAs
Quiz: identifying the benefits of DFMEAs
Who should attend
Individuals needing to identify, manage and mitigate risks using Design FMEAs (DFMEAs) and use a battery of related tools. The course covers all of the DFMEA requirements of AS13100:2021, the RM13004 document and the DFMEAs mandated in AS9145.
Having completed the course, individuals will be empowered to facilitate value-adding risk management projects that will form part of new product introduction (APQP & PPAP).
Apart from nominated ‘DFMEA Owners’ all persons involved in the DFMEA process will benefit from attending this course.
The objective is to qualify practitioners who will be ‘subject experts’ able to lead cross-function teams to undertake effective DFMEA projects.
Deliverables & benefits
The objective of this ‘face-to-face’ course and workshop is to qualify practitioners who will be ‘subject experts’ in Design Failure Mode and Effects Analysis (DFMEA).
Having completed this ‘face-to-face’ course and workshop, individuals will be empowered to facilitate value-adding DFMEA projects that will form part of new product introduction (APQP & PPAP).