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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 ‘face-to-face’ 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 ‘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 and Parameter diagram.

A combination of individual/team quizzes, tests and assignments are used to ensure understanding of the principles and practices involved.

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

Programme details

This ‘face-to-face’ course 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

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
  • 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
  • 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
  • FMEA project time
  • FMEA training and competency
  • Test: DFMEA owners, team members, and their competency

FMEA timeline in the PDP/APQP cycle

  • Timeliness of (all) FMEAs
  • Scheduling FMEAs in PDP/APQP cycle
  • Test: FMEA timeliness and timing in the PDP/APQP cycle

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
  • Sequence of the DFMEA steps/activities
  • Test: sequence of DFMEA steps/activities
  • DFMEA Linkages

DFMEA-specific terminology

  • 1a Item
  • 1b Function
  • 2 Failure Mode
  • Test: matching generic causes with examples
  • 3 Effect
  • Test: identifying poorly-worded effects description
  • 4 Severity [S]
  • AESQ & SAE severity ranking criteria
  • Test: assigning severity ratings scores to severity categories
  • Classification
  • 5 Cause
  • Test: identifying poorly-worded causes description
  • 6 Current design controls
  • a Occurrence [O]
  • AESQ & SAE occurrence ranking criteria
  • Test: assigning occurrence ratings scores to occurrence categories
  • 6b Detection [D]
  • 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
  • Test: prioritizing sequence for action using “S~O~D” values
  • Risk prioritization – for action
  • Systematizing the action plan
  • 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 & rescoring of RPN
  • Summarizing the key findings
  • Rescoring the S, O, D – and the ‘new’ RPN

Post DFMEA activities

  • Design verification plan
  • 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

Cost savings and benefits of DFMEA

  • Cost reasons for early deployment of DFMEAs (and PFMEAs)
  • 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) standard AS9145.

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.

Qualification

The objective of this ‘face-to-face’ course is to qualify practitioners who will be ‘subject experts’ in Design Failure Mode and Effects Analysis (DFMEA).

Having completed this ‘face-to-face’ course, individuals will be empowered to facilitate value-adding DFMEA projects that will form part of new product introduction (APQP & PPAP) standard AS9145.

This ‘face-to-face’ course has been formally approved by PROBITAS Authentication on behalf of the AESQ.

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