DFMEA

Design Failure Mode & Effect Analysis, Design Review & Design Validation Plan (DFMEA, DR & DVP) Dr K C Vora Deputy Director & Head, ARAI Academy, Academy, ARAI ARAI

New Pr odu od u c t Dev el o pme pm en t (NPD) Concept Phase Feasibility studies

Formulate development policy

List operational requirements

Definition Phase Draft several scheduling proposals Make tradeoffs

Define sys tem Define specifications

Solicit bids (when using subcontractors)

Design Phase General design

Production Phase Production process design

Detailed De tailed desig n Jigs, tools & equipment Make Ma ke protot ypes

Prototype testing Qualification testing

Pilot production Pilot evaluation

Full production startup Product launch

Market stage

New Pr odu od u c t Dev el o pme pm en t (NPD) Concept Phase Feasibility studies

Formulate development policy

List operational requirements

Definition Phase Draft several scheduling proposals Make tradeoffs

Define sys tem Define specifications

Solicit bids (when using subcontractors)

Design Phase General design

Production Phase Production process design

Detailed De tailed desig n Jigs, tools & equipment Make Ma ke protot ypes

Prototype testing Qualification testing

Pilot production Pilot evaluation

Full production startup Product launch

Market stage

House ou se of Quali uality ty QUALITY ELEMENTS Q-CHARACTERSTIC

QUALITY ELEMENTS CONFLICT IDENTIFICATION TABLE

CUSTOMER COMPLAINT DATA

CUSTOMER IMPORTENCE

VOC

BENCHMARKING BY CUSTOMER

CUSTOMER REQUIRE MENTS OR CR

QUALITY PLANNING

RELATIONSHIP MATRIX OR QFD TABLE- 1 OR QUALITY TABLE-1

CONCEPT DEVELOPMENTTABLE

TECHNICAL BENCHMARKING

BNE ISSUES COST ISSUE

PRODUCT PLANNING.

DESIGN TARGETS. RELIABILITY TARGETS TECHNICAL STUDY ITEMS

SUBSYSTEM

FUNCTION & SERVICE CONCERNS FT DIAGRAM

BOTTLENECK TECHNOLOGY ISSUES MECHANISM - AA

IMPACTED COMPONENTS A , B ,C

FMEA table ACTION PLAN TABLE

DFMEA

FMEA • FAILURE MODES & EFFECTS ANALYSIS (FMEA) is a paper-and-pencil analysis method used in engineering to document and explore ways that a product design might fail in real-world use. • Failure Mode & Effects Analysis is an advanced quality improvement tool. • FMEA is a technique used to identify, prioritize and eliminate potential failures from the system, design or  process before they reach the customer. • It provides a discipline for documenting this analysis for future use and continuous process improvement.

History of FMEA • Historically, FMEA was one of the first systematic techniques for failure analysis developed by the U.S. Military on 9th November, 1949. FMEA was implemented in the 1960’s and refined in the 70’s. It was used by reliability engineers working in the aerospace industry. • Then the Automotive Industry Action Group formed by Chrsyler, Ford & GM restructured the FMEA techniques which found a lot of importance in the automotive industry. • Since then FMEA has been instrumental in producing quality goods in the automotive sector.

Types of FMEAs • Design  – Analyzes product design before release to production, with a focus on product function.  – Analyzes systems and subsystems in early concept and design stages. • Process  – Used to analyze manufacturing and assembly processes after they are implemented.