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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 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.

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.

Programme 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.

Qualification

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).

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