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e-Learning: Design Failure Mode & Effects Analysis (DFMEA)

Programme 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’ to provide the basis of customizable documents/spreadsheets for immediate use.

The objective is to qualify practitioners who will be ‘subject experts’ able to lead cross-function teams to undertake effective DFMEA projects.

Programme 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

Programme 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.

Buy now

Buy e-Learning: Design Failure Mode & Effects Analysis (DFMEA)

The course is delivered as an online e-Learning module via the TEC Transnational Ltd learning platform - personalised for learners. Set the number of learners and provide their email addresses at the checkout.

e-Learning: Design Failure Mode & Effects Analysis (DFMEA)

£295

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