Confidential document of Innobest &

KGOC

Design Failure Mode Effect Analysis – BASIC

As per New AIAG VDA

Best Practices

K. Vishwanathan, Advisor – Business Excellence

Contact: Mobile – 98224 96850 Mail – [email protected]

Course Coverage

DFMEA - AIAG VDA Training Course

Material 1
Confidential document of Innobest &
KGOC

DFMEA – Course
Contents
• FMEA - Basic Purpose & Key Benefits
• Types & Categories of FMEA
• FMEA Objectives
• D & PFMEA Flow
• Inputs required for DFMEA
• Cross Functional Team – Roles & Resp
• DFMEA – Working Model & Detailed Work shop
• System, Sub – System, Component with various
levels & defining the relationships

DFMEA – Course
Contents
• Defining Scope
• Defining the interactions with respect to the scope
• Identification of 5 Noise Factors
• Defining the Functions
• Defining the Effects of the Interactions
• Defining Essential parameters for the designing a
product
• Construction of DFMEA
• Defining Design Review Check Points
• Defining Design Verification & Validation Plan
• Group exercises, Interaction & Conclusion

DFMEA - AIAG VDA Training Course

Material 2
Confidential document of Innobest &
KGOC

DFMEA Course –
Scope Clarifications

DFMEA Course –
Scope
• Product Structure Tree Diagram
• Boundary Diagram
• Item Function Work Sheet
• Interface Matrix
• Dr. Taguchi’s P – Diagram
• DFMEA Working Model & Application
• Design Review Check List – Guidance
• Design Review Check List - Guidance
• Robustness & Reliability (R & R) Check List -
Guidance

DFMEA - AIAG VDA Training Course

Material 3
Confidential document of Innobest &
KGOC

DFMEA Course –
Not the Scope
• QFD
• New Product Development Process (APQP)
• Production Part Approval Process
• PFMEA
• Proto Program
• GD & T
• Detailed Design Review check points
• Detailed Design Verification & Validation check
points
• Detailed R & R check points

DFMEA Course –
Not the Scope
• DOE
• Simulation Techniques (Software & Real life)
• Functional Testing Methods in detail
• DFM, DFA, DFS, DFSS – details
• Regulatory Requirements
• Restricted Material & Substances
• Problem Solving Structured Approach
• 2D & 3D software methods
• Poka Yoke

DFMEA - AIAG VDA Training Course

Material 4
Confidential document of Innobest &
KGOC

FMEA - Basic Information

FMEA – Definition &

General Information

• Structured Group Activity which

- Identify Potential Failure Modes
- Identify and Prioritize Actions
- Document the Process

• FMEA identifies Potential and confirm Critical

and Significant Characteristics to focus robust
control for reducing the risk.

DFMEA - AIAG VDA Training Course

Material 5
Confidential document of Innobest &
KGOC

FMEA – Definition &

General Information
• One of the best practices being followed since
1950s (EX: NASA, USA)
• One of the defect prevention tools
• Can be Applied to any process even for real life.
• Organization’s Knowledge bank
• Reduces the Risk for Customer and Organization
on the process and product
• Improves Customer Satisfaction

FMEA –
Implementation
• Important factor for successful implementation of an
FMEA program is “TIMELINESS”
• TIMELINESS means “Before – the – event” action not an
“after – the – fact” exercise.
• To Achieve the greatest value, the FMEA must be done
before a product or Process Failure Mode has been
incorporated into product or process.
• Product & Process Changes can be most easily and
inexpensively implemented and also will minimize late
change crises.

DFMEA - AIAG VDA Training Course

Material 6
Confidential document of Innobest &
KGOC

FMEA – Purpose
• DISASTER happens if we don’t deliver what the
customer wants and the product does not reliably function
• UNRELIABLE PRODUCTS result if we deliver what the
customer wants, but the product does not reliably
function
• RELIABLE PRODUCTS / CUSTOMER DOES NOT
WANT happens when product fulfills all functions, but
is not what customer expects
• EXCELLENT PRODUCTS results when we deliver what
customer wants and product fulfills all functions
• FMEAs get the failure out of the products

FMEA – Benefits

• Improves the Quality, Reliability and Safety of the

evaluated products
• Reduces product redevelopment timing and cost
• Aids in the development of robust DVP & CP
• Helps Engineers prioritize and focus on eliminating
product and process concerns and helps prevent problem
from occurring
• Identified Critical and Significant characteristics (Special
Characteristics)
• Acting as a “lessons learnt tool”.

DFMEA - AIAG VDA Training Course

Material 7
Confidential document of Innobest &
KGOC

FMEA – Benefits
What this chart indicates?
45
40
35
30
25
20
15
10
5
0
Design Supplier Mfg. process

FMEA – Benefits
• The chart in the previous slide explains the percentage of
field failures attributed to major three categories defined.

• Almost 50% of the problems are due design which could

have been avoided if FMEAs are completed in Design
Stage.

• This info is based on major OEM’s study on field failures

in the year 2000.

• Leading to Achieving Internal Benefits (Cost reduction in

the organization) and External Benefits (Customer
Satisfaction)

DFMEA - AIAG VDA Training Course

Material 8
Confidential document of Innobest &
KGOC

Factors for Field Failure

What this chart indicates?

30%

25%

20%

15%

10%

5%

0%
Int Wear P - P
usage out Varn

Factors for Field Failure

There are 5 basic factors which can lead to Field
Failure:

• Internal Conditions of Usage

( ex: System Interaction)
• External Conditions of Usage ( ex: Road, Climate)
• Changes in dimension over time or mileage
(ex: Wear, fatigue)
• Customer Usage
• Piece to Piece variation

DFMEA - AIAG VDA Training Course

Material 9
Confidential document of Innobest &
KGOC

FMEA – Types &

Categories
Types Categories

Concept Design & Process Concepts

Design System, Sub-System & Component

Process Assembly – System, Sub-System, Component

Manufacturing – System, Sub-System, Component

Machinery System, Sub-System & Component

FMEA – Application &

Categories

Applications Categories

Environment System, Sub-System & Component

Attribute System, Sub-System & Component

Software System, Sub-System & Program level

DFMEA - AIAG VDA Training Course

Material 10
Confidential document of Innobest &
KGOC

Concept FMEA – Key

Benefits

• Helps identity the optimum concept alternatives

• Identifies Potential Failure Modes and Causes due to
interactions within the concept
• Increases in chances of capturing all the potential
effect of a proposed concept’s Failure Modes
• Helps generate cause occurrence ratings that can be
used to estimate a particular concept alternative’s
target

Concept FMEA –Key

Outputs
• A list of Potential concept Failure Modes and
Causes
• A list of design actions to eliminate the causes of
Failure Modes or reduce their rate of occurrence
• Specific Operating parameters as key
specifications in the design
• New test methods or recommendations
• Decision on which concept to pursue

DFMEA - AIAG VDA Training Course

Material 11
Confidential document of Innobest &
KGOC

Design FMEA – Key

Benefits
• The Design FMEA supports the design process in
reducing the risk of failures by:
- helping in the objective evaluation of design,
including functional requirements & design
alternatives
- Providing future reference like Lessons
Learned to aid in analyzing field concerns,
evaluating design changes and developing
advanced designs

Design FMEA – Key

Benefits

• Helps in identifying potential special characteristics

• Helps in validating the Design Verification Plan
• Focusing on Potential Failure Modes of Products
caused by Design deficiencies
• Identify current Design controls and additional
controls to rectify the design deficiencies
• Helps in Making robust design

DFMEA - AIAG VDA Training Course

Material 12
Confidential document of Innobest &
KGOC

Design FMEA – Key

Outputs
• A list of Potential Product Failure Modes and Causes
• A list of Potential Critical and Significant Characteristics
• A list of recommended actions to reduce severity,
eliminating causes of product failure modes or reducing
their rate of occurrence or improving detection
• Confirmation of DVP
• Feed back of design changes to the design team
• A List of Design controls to
• Prevent a Design mistake
• Detect a Design mistake
• Detect a functional problem during testing

Process FMEA – Key

Benefits

• Identifies Potential Product related Process Failure Modes

• Assesses the Potential Customer effects of the failures
• Identifies Potential manufacturing or assembly process
causes for reducing the occurrence
• Develops a ranked list of Potential Failure Modes for
establishing the priorities for corrective actions plan
• Document the results of Manufacturing or Assembly
process
• Identifies confirmed Critical and Significant characteristics

DFMEA - AIAG VDA Training Course

Material 13
Confidential document of Innobest &
KGOC

Process FMEA – Key

Benefits

• Identify Operator safety concerns

• Feed back on design changes required and manufacturing
feasibility
• Helps in development of elaborate manufacturing or
assembly control plans.
• Confirming the need for special controls in manufacturing
process

Process FMEA – Key

Outputs
• A list of Potential Product Failure Modes and Causes
related to process
• A list of Critical and Significant Characteristics
• A list of Operator Safety Areas
• A list of recommended actions to reduce or eliminate the
process related causes
• Serving as a key input for Control Plan
• Identified areas of Work Instruction in process stages
• A List of Process controls to
• Prevent a Process mistake
• Detect a Process mistake
• Detect a failure mode

DFMEA - AIAG VDA Training Course

Material 14
Confidential document of Innobest &
KGOC

Machinery FMEA –
Key Benefits

• Helps in Identifying the Break down details and major

functions of the Equipment
• Identifies the cause of Break down or poor performance of
the Equipment
• Helps in improving the current design controls and
Preventive Maintenance effectiveness
• Helps in implementing TPM effectively

Machinery FMEA –
Key Outputs

• A list of Functional Failures or Break downs

• A list of mechanisms which will lead to the failures

• Identification of Significant and Critical mechanisms based

on the effect of the failures

• A list of current PM checks and recommended PM checks

• Serving as input for effective Break down analysis

DFMEA - AIAG VDA Training Course

Material 15
Confidential document of Innobest &
KGOC

Process Flow of DFMEA & PFMEA

FMEA Flow for Product

and Process Design
Product Structure Tree Diagram
↓
Boundary Diagram
↓
Item Function Work Sheet
↓
Interaction Matrix
↓
Parameter Diagram
↓

DFMEA - AIAG VDA Training Course

Material 16
Confidential document of Innobest &
KGOC

FMEA Flow for Product

and Process Design
DFMEA
↓
RRC
↓
DRC
↓
DVP
↓
Engineering Drawing /
Spec finalization
↓

Product and Process

Design Sequence
Process Flow Diagram
↓
PFMEA
↓
Control Plan
↓
Process & Tooling Design Finalization
↓
Process Instructions
↓
Product / process Validation

DFMEA - AIAG VDA Training Course

Material 17
Confidential document of Innobest &
KGOC

DFMEA – Key Steps

DFMEA – Key steps

• Team Formation
• Establish Scope
• Inputs to DFMEA - Product Structure Tree
- Boundary Diagram
- Interaction Matrix
- Item Function Work Sheet
- P Diagram
• Identification of Potential Failure Mode
• Estimate the potential Risk / Effect of the Failure

DFMEA - AIAG VDA Training Course

Material 18
Confidential document of Innobest &
KGOC

DFMEA – Key steps

• Ranking Severity
• Identification of Potential Critical & Significant
Characteristics
• Identification of Potential Cause of the Failure
• Ranking the Occurrence
• Identification of Current Design Controls in terms of
Prevention and Detection
• Ranking the Detection
• Estimating the overall risk by identifying the RPN for the
causes / Failure Mode

DFMEA – Key steps

• Identifying the Actions to reduce / eliminate the Failure
Mode
• Estimating Revised RPN after action validation
• Deriving Design Review Check list from DFMEA
• Deriving Design Verification Plan from DFMEA
• Complete / Update Robustness & Reliability Check List
• Periodical Review by Team focusing on Design
improvements / Changes
• Sharing companywide TGW / TGR as part of Knowledge
Sharing Process

DFMEA - AIAG VDA Training Course

Material 19
Confidential document of Innobest &
KGOC

Cross Functional Team – Roles & Inputs

Senior Management Team’s

- Key responsibilities
• Program Management Team consists of all HODs
(Apex Team)

• To ensure Project specific program management teams

are from all relevant functions like Design,
Manufacturing, Quality, Tooling, Maintenance,
Marketing, Purchase, etc. (Cross Functional Teams) and
are effective.

• To review the status of all new product development

atleast once a month to fulfill the customer /
organisation’s expectations.

DFMEA - AIAG VDA Training Course

Material 20
Confidential document of Innobest &
KGOC

Project specific CFTs

• Team formed by Apex Management group

• Consist of experts from Design, Manufacturing,

Methods / Tooling, Maintenance, Procurement, QA,
Supplier Quality, Any other related experts…(Service,
Testing…)

• Right skill sets are ensured among the team members and
roles are defined by Apex Management Group.

CFT – Key
Responsibilities
• As a cross functional team, to make sure the activities
performed are as per the Launch requirement including
PPAP.
• To get involved in effectively carrying out
D & PFMEAs, PFD, CP, SPC, MSA, PPAP including WI.
• To ensure the activity completion as per the check points
under “ Program Management Responsibility” for every
stage.
• In appropriate stages, to ensure the Customer and supplier
involvement in new product launch.

DFMEA - AIAG VDA Training Course

Material 21
Confidential document of Innobest &
KGOC

Team Brain Storming

HOW WHO

WHEN
WHERE
WHAT
WHY

Brain Storming – guide

lines
• No interruptions during the team discussion / analysis
(preferably sit away from the work place)
• All ideas generated by the team must be recorded
• During the brain storming, all team members are having
equal status. No leader, boss & sub-ordinate approach.
• Clear agenda for brain storming to be defined in advance
• Time duration for brain storming will be 10 min to 2 hrs
(max)
• Everyone should be encouraged to tell their points openly.
• Don’t encourage unnecessary arguments and discussions.

DFMEA - AIAG VDA Training Course

Material 22
Confidential document of Innobest &
KGOC

Cross functional teams

- Design FMEA
• Design, Manufacturing, Quality, Tooling Design,
Marketing, Servicing, Testing
• People in the team should be knowledgeable on the
functions of the product
• Should be experienced in the respective field
• Should be knowledgeable regarding the application of the
product
• Service History / Field Experience of Similar Design Data
including warranty information
• Environmental Conditions at the usage point
• Development Test Results (Similar Design Data)

Input to Cross functional

teams - Design FMEA
• Pre-Production Sample & Proto results
• Vehicle durability (Verification) & Test Results
(Validation)
• Material Compatibility Study Results
• Tolerance Stack up Study Results, In-house Manufacturing
& Assembly data for the past 1 year (min) – including
DFM & DFA summary data
• Supplier Manufacturing & Assembly data for the past 1
year (min) – including DFM & DFA summary data
• Internal Data Sharing (From Partners, Other Plant
locations, Informations from other Design Centers, etc)
• Regulatory Requirements (Country wide in case of
exports)

DFMEA - AIAG VDA Training Course

Material 23
Confidential document of Innobest &
KGOC

Input to Cross functional

teams - Design FMEA
• Summary Voice of Customer Data / Market Data
(derived from QFD & other surveys)
• Customer / Service – Data on their usage pattern
(specifically region wise)
• Bench Mark Information
• Competition Information
• New Technology related information
• User, Dealer, Distributors, Service and other
partners feedback on existing models (including
complaints)

Input to Cross functional

teams - Design FMEA
• Restricted Material list (Country wide in case of exports)
• Earlier TGW / TGR summary
• Earlier Design Changes Summary
• Management Expectations
• Core Product related requirements
• Similar Design’s Process FMEA
• Key Primary and Secondary functions (broader level)
• Incidents of wrong assembly, Manufacturing variation due
to design, Other Manufacturing & Assembly Errors – Data
• Current Design controls & facilities
• Existing Verification & Validation methods

DFMEA - AIAG VDA Training Course

Material 24
Confidential document of Innobest &
KGOC

Input to Cross functional

teams - Design FMEA

• List of Material Standards, Dimensions &

Tolerancing Standards
• Similar Drawing, Sketches for better visualization
to improve the thought process of the team
• Reliability, Maintainability, Durability
Serviceability, Quality, Weight, Life, Cost Targets
• Any other key inputs decided by team based on
their experience……

Product Structure Tree – Example

of Construction and Application

DFMEA - AIAG VDA Training Course

Material 25
Confidential document of Innobest &
KGOC

Product structure Tree (PST) for

System / Subsystem / Component

• Include all the subassemblies and the components in the

assembly
• Helps in visualizing the assembly of the product
• Applicable only if the product is assembly oriented
• Helps in identifying the functions of the product at each
level
• Used for finalizing BOM

Simple Product structure Tree

(PST) – Real Life Example
Example of a Simple Writing Pen (Refer Visual in next slide)

Pen System

Cap Assembly Neck, Body & Sub-System

refill Assy
Level - 1

Refill Assy Sub-System

Level - 2

Nib Assy Sub-System

Level - 3

Cap Clip Neck Body refill tube Nib Ball Refill cap Ink Spring Component

DFMEA - AIAG VDA Training Course

Material 26
Confidential document of Innobest &
KGOC

Visual display of a Pen

– PST Items - Example
Neck, Body, Refill Assy
Nib Assy
Cap Clip (Nib & Ball)

Spring

Refill
Tube
Cap Assy Neck Body
Refill
Ink Cap
Refill
(inside) Assy

PST – Automotive
Example - Car

Car System

Engine Suspension Electrical Sub-System

System System Systems
Level - 1

Sub-System
Front Rear Level - 2

Axle Beam Shock Absorber Assy Sub-System

Level - 3

Spindle Seat R Braket Bracket Nut R Sh Shock Bolt RR Nut RR Component

Comp Spring T Arm Flex hose Absorber Absorber Shock Shock

DFMEA - AIAG VDA Training Course

Material 27
Confidential document of Innobest &
KGOC

Product Structure Tree Diagram

Group Activity & Presentation
Time Limit: 0.5 hrs (max)

Boundary Diagram – Example of

Construction and Application

DFMEA - AIAG VDA Training Course

Material 28
Confidential document of Innobest &
KGOC

Establish Scope through

Boundary Diagram

• Boundary Diagrams are mandatory for breaking the

FMEA into manageable levels.

• Prioritize whether scope is system / sub-system /

component from PST and prepare the boundary diagram

• Acts as valid input to Interface Matrix, Item Function

work sheet, P-Diagram thereby the robust DFMEA
completion.

Establish Scope through

Boundary Diagram

• Defines the Item Boundary & the Scope (Focus Area)

• Clarifies the relationships between the focused Item and

the interfacing Systems / items

• All PST items are not to be duplicated in the name of

Boundary Diagram

• Only relevant blocks / items which are essential part for

designing the scope are addressed in Boundary Diagram

DFMEA - AIAG VDA Training Course

Material 29
Confidential document of Innobest &
KGOC

Establish Scope through

Boundary Diagram
• If the hardware blocks are in physical contacts in vehicle,
identify with ßà
• If the hardware blocks are not in physical contact but there
will be flow of energy / information, identify with à
• Identify the blocks which can interact with Environment
with ‘E’ on the top
• Identify the blocks which can get affected by customer
usage as ‘C’ on the top
• Identify the blocks where the physical wear can take place
as * on the top
• Boundary Diagram must be reviewed and updated once
again after addressing Item Function Work Sheet

Simple Boundary Diagram –

Example of Pen

Refill Nib
Assy Assy Environment
C, E, W/T - Temp
- Humidity
C, E, W/T C, E, W/T - Dust, etc

Cap Refill
Ball Neck, Cap
Assy Customer
C&E Body & C&E usage
Refill Assy
Nib Ink
C & W/T Wear & Tear
Refill
Neck Tube External
System

Body Spring Manuf.

C & W/T variation

DFMEA - AIAG VDA Training Course

Material 30
Confidential document of Innobest &
KGOC

Simple Boundary Diagram – Automotive

Example – Shock Absorber

Lower
Bump C, E, W/T Bush & Environment
Stopper Sleeve - Temp
- Humidity
Upper C, E, W/T - Dust, etc
Bush &
Axle sleeve Rear Customer
Beam
C&E Shock E & W/T
usage
Absorber Ex: Bad
Piston Outer driving
Rod Tube
Lateral Sub Sub
Assy Wear & Tear
Rod Assy
Inner
Oil Tube External System
Tyre &
Sub Assy
Wheel

Boundary Diagram
Group Activity & Presentation
Time Limit: 0.5 hrs (max)

DFMEA - AIAG VDA Training Course

Material 31
Confidential document of Innobest &
KGOC

Item Function Work Sheet –

Example of Construction and
Application

Item Function Work sheet

• Item Function work sheet is the tool for

determining the functions and its corresponding
specifications.
• Primary functions, secondary functions and
Potential failure mode also addressed in Item
function Work sheet
• Serving as an input for addressing Potential
Failure Mode in DFMEA.

DFMEA - AIAG VDA Training Course

Material 32
Confidential document of Innobest &
KGOC

Item Function Work sheet

• Use Item function worksheet

– Write the function in Verb noun
– Write the specification of the function ( How
much ? And When the function has to be
performed)
– Identify Primary and Secondary functions
– Give ranking to prioritize every secondary
functions

Item Function Work sheet

• List all the functions that meets the Design intent

• Guidelines for defining the function
– What is the product supposed to do ?
– What is the product not supposed to do ?
– When it has to do/not to do the function?
Includes the Operating and usage conditions
– How much (specification) it has to do the
function?

DFMEA - AIAG VDA Training Course

Material 33
Confidential document of Innobest &
KGOC

Item Function Work sheet

• Ranking the Secondary functions (1-4)
1 - Very important - Is an important secondary function
and if not met may affect primary function and
customer will be very dissatisfied
2 - Important - Customer will be dissatisfied
3 - Moderate - Average customers might noticed this
failure of function
4 - Most customers will not be able to notice this
failure
• Take all the primary functions and Secondary functions
with ranking 1 and 2 for further analysis

Defining Functions
• A well defined Function / Requirement will lead to
Reliable and Robust Design
• Consider Following Inputs to capture most functions:
- Global Customer Requirements
- System & Sub-System Design Spec
- Engineering Specifications
- Design Verification plan & Sign off
- QFD
- Regulatory Requirements
- Other essential inputs

DFMEA - AIAG VDA Training Course

Material 34
Confidential document of Innobest &
KGOC

Item Function Work sheet -

Example
Functions Primary / Priority How much? When?
Secondary
To Write Primary 1 1) 0.5 mm thick, Whenever desired to
smoothly 2) 10 miles write by users (in all
(Writing Pen) weather conditions)

To Stop the Primary 1 Within X feet from Y Whenever brake pedal

vehicle speed in Z pedal force is applied by users (In
(Braking system) all weather conditions)

To raise the Primary 1 To X feet from ground Whenever the power

vehicle for tire level within Y seconds switch is pressed by
change (Jack under Z force limits users (In all weather
Assembly) conditions)

Item Function Work

sheet - Example
Ex: Wiper Assembly

1. To Wipe the water in the windscreen - Wiping angle and

speed (specification) - During rains when switched on
(Primary)
2. Should wipe without noise - When working (Secondary)
3. Should not damage the windscreen in the long run
(Secondary)
4. Should come back to the rest position - When switched off
(Primary)
5. Should wipe at the specified speed - When switched on and
the speed is set (Primary)

DFMEA - AIAG VDA Training Course

Material 35
Confidential document of Innobest &
KGOC

Item Function Work sheet

Group Activity & Presentation
Time Limit: 0.5 hrs (max)

Interaction Matrix – Example of

Construction and Application

DFMEA - AIAG VDA Training Course

Material 36
Confidential document of Innobest &
KGOC

Interaction Matrix
• Quantifying the system interactions
• If interactions are not addressed, it may lead to potential
warrenty / recall issues.
• Mandatory for all new designs
• Used to check the validity of the completed causes in
DFMEA
• Every interaction both positive and negative should be
verified
• Negative interactions are analyzed further for corrective
action recommendations
Note: Refer Subsequent slide for example of Pen
(partially completed to explain the technique)

Interaction Matrix

P: Physically Touching
E: Energy Transfer
P E
I : Information exchange I M
M: Material exchange

+2: Interaction is necessary for the function

+1: Interaction is beneficial but not absolutely necessary for functionality
0 : Interaction does not affect the functionality
-1: Interaction causes negative effects but does not prevent functionality
-2: Interaction must be prevented to achieve functionality

DFMEA - AIAG VDA Training Course

Material 37
Confidential document of Innobest &
KGOC

Interaction Matrix – Pen Example

Interaction Matrix – Automotive

Example – Shock Absorber
Rear Shock oil Outer Tube Inner Tube
Absorber Sub Assy Sub Assy

Rear - - - - - -
Shock
Absorber
- 0 - - - -
+2 +2 +2 +2
Oil
- - - -
Outer +2 +2
Tube Sub
Assy - -
Inner
Tube Assy

DFMEA - AIAG VDA Training Course

Material 38
Confidential document of Innobest &
KGOC

Interaction Matrix
Group Activity & Presentation
Time Limit: 0.5 hrs (max)

Dr. Taguchi’s P - Diagram –

Example of Construction and
Application

DFMEA - AIAG VDA Training Course

Material 39
Confidential document of Innobest &
KGOC

Dr. Taguchi’s P - Diagram

• Dr. Taguchi created the P-Diagram to utilize as an aid in
parameter design

• Significant Design Attributes are Outlined in a visual way

• Represents the transmission of an input signal to the

functional output under the influence of control factors

• Noise is considered with the relationship with Ideal output

function and Potential Causes of Failure Mode

• Cross Functional Team Effort must be demonstrated in

constructing P - Diagram (Parameter Diagram)

Dr. Taguchi’s P - Diagram

• Describes Noise Factors, Control Factors, Ideal Functions
and Error States

• Assists in Identification of:

- Potential Cause of the Failure

- Potential Failure Modes
- Potential Effect of the Failure
- Current Controls &
- Recommended Actions

DFMEA - AIAG VDA Training Course

Material 40
Confidential document of Innobest &
KGOC

Construction of P - Diagram
Noise Factors
Piece to Piece Variation Customer Usage Pattern Systems Interactions

Wear Out External Environment

Input System / Sub- Output

System
(Signal) (Response)
(Scope)
Ideal Functions

Control Factors Error States

(Design, Mechanical, (Type 1 & 2)
Chemical, Electrical, etc)

Blank P – Diagram - sample

DFMEA - AIAG VDA Training Course

Material 41
Confidential document of Innobest &
KGOC

Automotive P – Diagram –
Rear shock Absorber

Dr. Taguchi’s P – Diagram

– Control Factors Example
• Control Factors are the means to make the Item’s Function more Robust

Design Controls:
- International Standard for Material Selection
- JIS / DIN / IS for Dimensioning & Tolerancing (Spec)
- Proto Validation
- Software Simulation
- Product Endurance Testing

Mechanical Control:
- Mounting Materials
- Packaging Locations and Volume
- Cover / Housing design and material

Chemical Control:
- Coating material & thickness spec

DFMEA - AIAG VDA Training Course

Material 42
Confidential document of Innobest &
KGOC

Dr. Taguchi’s P – Diagram

– Error States Example
• Two Types of Errors are to be considered

Type 1 Error: Major Failure mode (with respect to Item’s Function)

Example: No Leak à Item Function Requirement

Leak à Potential Failure Mode
(Consider all types of Major Potential Failure Mode for the identified
Item’s Function)

• Type 2 Error: Major Effects of the Failure (With respect to Potential

Failure Mode of the Item’s Function)

Example: Brake Failure (If Oil Leakage is present)

Endanger Safe vehicle operation without warning
(Consider all types of Major Effects in all the subsequent categories of
customers )

Dr. Taguchi’s P – Diagram – Noise

Factors, Responses & Signal Factors
• Noise Factors:

Unintended interfaces, or conditions and interactions that

may lead to failure of the function

• Responses:

Ideal, Intended Functional Output

• Signal Factors:

Input which triggers the function being analyzed

DFMEA - AIAG VDA Training Course

Material 43
Confidential document of Innobest &
KGOC

Dr. Taguchi’s P - Diagram – Group

Activity & Presentation
Time Limit: 0.5 hrs (Max)

DFMEA – Example of
Construction and Application

DFMEA - AIAG VDA Training Course

Material 44
Confidential document of Innobest &
KGOC

DFMEA – AIAG VDA - 7 Step

Approach

Step 1: Planning & Preparation

Step 2: Structure Analysis
Step 3: Function Analysis
Step 4: Failure Analysis
Step 5: Risk Analysis
Step 6: Optimization
Step 7: Result Documentation

DFMEA – AIAG VDA Format

Current Current
Design Design DFMEA Action results
controls controls

C
D
L F Respon
O
Potential M sibility D
Potential Potential S C D Recomm
Causes/ E & target F
Item / Function Failure Effects of E A C E ended
Mechanisms A comple M
Mode Failure V T action
of failure tion S O D E
S Actions
Prevention Detection A date E C E A
taken
P V C T
S A
P

Sample Format

DFMEA - AIAG VDA Training Course

Material 45
Confidential document of Innobest &
KGOC

DFMEA – Header Information

• Model Years / Program

• Core Team
• Design Responsibility
• Key Date
• FMEA Number
• Prepared By
• FMEA Date (Latest Revision Date):

Identify the potential

failure modes

• Opposite of function
• Manner in which the assembly,sub-assembly,component
will fail to meet the design intent
• Should be written for all the primary functions and
secondary functions having ranking 1 & 2
• Assumption made - Failure mode could occur but may not
necessarily occur
• Use the following to aid in defining failure modes
– Warranty reports
– Customer complaints

DFMEA - AIAG VDA Training Course

Material 46
Confidential document of Innobest &
KGOC

Various types of
potential failure modes

• Generally Four Type of Failure Mode Occur

1) No Function,
2) Partial / Over / Degraded Function,
3) Intermittent Function,
4) Unintended Function
• The First and second types apply often and should be the
most commonly seen.
• The third and Fourth types are typically missed when
performing the FMEA which are also very important for
the product robustness

Various types of
potential failure modes

• No Function: System or design is totally inoperative

• Partial / Over / Degraded Function: Meets some of the
spec but does not fully comply with all requirements. This
includes over function / degraded functions over a period
of time
• Intermittent Function: Complies but loses some
functionality or inoperative due interaction
• Unintended Function: Interaction of several elements will
adversly impacts the product and leading to undesirable
performance

DFMEA - AIAG VDA Training Course

Material 47
Confidential document of Innobest &
KGOC

Identify Various types of potential

failure modes using Item Function Table
Function Primary / How When?
Secondary much? Potential Failure Mode Types
No Partial Intermittent Over Degraded Un
Function Function Function Function Function Intended
Function

Identify the potential

failure modes
• Ask the following questions for each function in the Item
function worksheet
– Will it not totally perform the function. Total failure of
the function
Ex : Not wiping the water

– Will it fail to do the function only under certain “When”

conditions or under all “When conditions”
Ex: Not Functioning during rainy / Winter
Season

– Will it do a function when it is not supposed to do the

function
Ex: Creating noise during wiping

DFMEA - AIAG VDA Training Course

Material 48
Confidential document of Innobest &
KGOC

Identify the effects of

the failure mode
• Effects are defined on
– Next higher assembly, Vehicle, User of the vehicle,
Government (Regulations)
• Ask the following questions
– If this failure mode occurs, what will happen to the next
higher assembly – Function? What Way?
– If this failure mode occurs, will it affect the functioning of
the vehicle and in what way
– If this failure mode occurs, will it be felt by the customer
and how it will be felt
– Will it create any violation to the government regulation

Identify the effects of

the failure mode

• Do not consider any current design controls

(Tests) which might detect the failure mode

• Effect on next higher assembly will become a

Failure mode for the next higher assembly

DFMEA - AIAG VDA Training Course

Material 49
Confidential document of Innobest &
KGOC

Severity Ranking Table –

DFMEA – AIAG
Corporate or
Product Line
Effect Severity Criteria S Examples
Affects safe operation of the vehicle and /or other vehicles, the health of 10
driver or passenger (s) or road users of pedestrians
Very High
Noncompliance with regulations 9

Loss of primary vehicle function necessary for normal driving during 8

High expected service life
Degradation of primary vehicle function necessary for normal driving during 7
expected service life
Loss of secondary vehicle function 6

Moderate Degradation of secondary vehicle function 5

Very Objectionable appearance, sound, vibration, harshness, or haptics 4

Moderately Objectionable appearance, sound, vibration, harshness, or 3

haptics
Low

Slight Objectionable appearance, sound, vibration, harshness, or haptics 2

Very Low No discernible effect 1

Identifying SC and CC

• If the Severity number is 9 or 10, all root causes (Part

characteristics) of that failure mode are identified as
Potential Critical characteristics (‘CC’)
• If the Severity number is 5,6,7,8 then the root causes of
that cause are Potential Significant characteristics (‘SC’)
• Potential Critical and Significant characteristics are
“confirmed” as Critical and Significant in the Process
FMEA
• Mark ‘SC’ and ‘CC’ in the Special characteristic column
to indicate the causes as Potential significant or critical

DFMEA - AIAG VDA Training Course

Material 50
Confidential document of Innobest &
KGOC

Identifying the Causes

• Indication of a design weakness which leads to the

failure mode

• Every conceivable cause/failure mechanism

should be identified for every failure mode

• Start with the failure modes that have the highest

severity rating

Identifying the Causes

• When doing the FMEA for the assembly ask the following
questions
– What are the sub-assembly/component failures that
could result in the failure mode (Failure in the
functioning of the assembly)?
– Is there any assembly design deficiencies that could
result in this failure mode, Is there any sub-assembly/
component design deficiencies that could result in the
failure mode?
– Is there any abuse by the user which could result in this
failure mode, Is there any wrong assembly/wrong
application by the OEM customer because of which the
failure mode will happen?

DFMEA - AIAG VDA Training Course

Material 51
Confidential document of Innobest &
KGOC

Identifying the Causes

• This will identify the first level design cause
• First level cause is the immediate cause of a failure mode
• If the first level cause is not identified and described in
terms of a part characteristic, then it is not the root cause.
Go down further to identify the root causes
• Continue the Root cause analysis till we get a cause which
describes a part characteristic
• Use FTA, Brainstorming to determine Root cause
• Causal analysis should stop only if we get a cause which is
a part characteristic

Identifying the Causes

• Sometimes a failure mode happens only if two or

more causes occur together (Interaction)
• Highlight these causes to indicate that the failure
mode happens only if the causes occur in interaction
• Design Actions should be taken only on the root
causes
• Both first level causes and Root causes should be
documented in the Design FMEA

DFMEA - AIAG VDA Training Course

Material 52
Confidential document of Innobest &
KGOC

Identifying the Causes

Caution - 1:

• Assume that the causes are because of design

deficiencies and the assembly is made as per the
drawings spec.(Direct Design Causes)
• In that case, Ask following questions:
- What could cause the item to fail in this
manner?
- What circumstances could cause the item to
perform its function?

Identifying the Causes

Caution – 1 Examples:

• Material Spec incorrect

• Material hardness specified too low / high
• Torque specified too low / high
• Inadequate design life assumption
• Lubricant specified too viscous
• Tolerancing incorrect
• Effect on accumulation of tolerance (Stack up)

DFMEA - AIAG VDA Training Course

Material 53
Confidential document of Innobest &
KGOC

Identifying the Causes

Caution – 2:
• The design deficiencies do not directly lead to the
functional failure, but leads to a manufacturing
error which leads to a functional failure

• This feed back has to be given by the

Manufacturing & Quality Members in the CFT

• Reference data: Monthly Pareto chart, In-house

rejection data, Supplier performance report,
information, etc

Identifying the Causes

Caution – 2 Example:

• Torque Variation because access hole is

designed off location

• Outer Dia Variation because hardness

specified is wrong

• Tool breakage due to high hardness

specified

DFMEA - AIAG VDA Training Course

Material 54
Confidential document of Innobest &
KGOC

Identifying the Causes

• Questions to be asked

– Is orientation or alignment important to how the item

will function
– Can the component be assembled upside down or
backwards or is there a chance that the component will
not be assembled
– Are specifications compatible with manufacturing
process

Identifying the Causes

Caution – 3,4,5,6:
• Failure may occur due to Interaction related
causes
EX: 1) System Interaction
2) Customer Usage
3) Wear & Tear
4) Environmental Effect

Refer Interaction Matrix & P – Diagram for

addressing these causes

DFMEA - AIAG VDA Training Course

Material 55
Confidential document of Innobest &
KGOC

Identifying the Causes

Caution - 7:

• During the brain storming, sometimes a process cause may

also be identified by the team

• Example
– Hand Brake Failure – Why?
– Cable Loose – why?
– Crimping Variation in the process- Process cause

• Remove the process cause from the DFMEA and address

in the Process FMEA

Identifying the Failure Mechanism &

Causes
Failure Mode Mechanism Cause

1. Master Cylinder vacuum

lock due to seal design
No transfer of force
Vehicle does not stop from pedal to pads 1. Loss of hydraulic fluid due
to hydraulic lines crimped /
compressed (inappropriate
tube material specified)
Vehicle can not move Hydraulic pressure Master Cylinder vacuum lock
does not release due to seal design

Stops vehicle with more Excessive transfer Cumulative pressure build up

than -- of force of force from pedal in master cylinder due to seal
to pads design

DFMEA - AIAG VDA Training Course

Material 56
Confidential document of Innobest &
KGOC

Occurrence Potential (O) for the

Product – DFMEA – AIAG VDA
Corporate or
Prediction of Product Line
Failure Cause Occurrence Criteria O Examples
Occurring

Detail changes to known design (same application, with minor

change in duty cycle or operating conditions) and testing or field
experience under comparable operating conditions, or new design
Low with successfully completed test procedure. 3
Design expected to conform to Standards and Best Practices,
considering Lessons Learned from previous designs. Prevention
controls capable of finding deficiencies in the product related to the
failure cause and predict conformance of production design.
Almost identical mature design with long term field exposure. Same
application, with comparable duty cycle and operating conditions.
Testing or field experience under comparable operating conditions.
Design expected to conform to standards and best practices, 2
Very Low
considering Lessons Learned from previous designs, with significant
margin of confidence. Prevention controls capable of finding
deficiencies in the product related to the failure cause and indicate
confidence in design conformance.

Extremely Low Failure eliminated through prevention control and failure cause is not 1
possible by design

Occurrence Potential (O) for the

Product – DFMEA – AIAG VDA
Prediction of Corporate or
Failure Cause Product Line
Occurring Occurrence Criteria O Examples

Similar to previous designs, using existing technology and materials. Similar

application, with changes in duty cycle or operating conditions. Previous
testing or field experience.
High Standards and design rules exist but are insufficient to ensure that the failure 6
cause will not occur. Prevention controls provide some ability to prevent a
failure cause.

Detail changes to previous design, using proven technology and

materials. Similar application, duty cycle or operating conditions. Previous
testing or field experience, or new design with some test experience related
to the failure.
Design addresses lessons learned from previous designs. Best Practices re- 5
evaluated for this design but have not yet been proven. Prevention controls
capable of finding deficiencies in the product related to the failure cause and
provide some indication of performance.
Moderate
Almost identical design with short-term field exposure. Similar application,
with minor change in duty cycle or operating conditions. Previous testing or
field experience.
Predecessor design and changes for new design conform to best practices, 4
standards, and specifications. Prevention controls capable of finding
deficiencies in the product related to the failure cause and indicate likely
design conformance.

DFMEA - AIAG VDA Training Course

Material 57
Confidential document of Innobest &
KGOC

Occurrence Potential (O) for the

Product – DFMEA – AIAG VDA
Prediction of Corporate or
Failure Cause Product Line
Occurring Occurrence Criteria O Examples

First application of new technology anywhere without operating experience

and/or under uncontrolled operating conditions. No product verification and/or
Extremely HIgh validation experience. 10
Standards do not exist and best practices have not yet been determined.
Prevention controls not able to predict field performance or do not exist.
First use of design with technical innovations or materials within the
company. New application or change in duty cycle / operating conditions. No
product verification and/or validation experience.
Prevention controls not targeted to identify performance to specific 9
requirements.

Very High
First use of design with technical innovations or materials on a new
application. New application or change in duty cycle / operating conditions.
No product verification and/or validation experience. 8
Few existing standards and best practices, not directly applicable for this
design. Prevention controls not a reliable indicator of field performance.
New design based on similar technology and materials. New application or
change in duty cycle / operating conditions. No product verification and/or
validation experience.
High Standards, best practices, and design rules apply to the baseline design, but 7
not the innovations. Prevention controls provide limited indication of
performance

Occurrence Potential (O) for the

Product – DFMEA – AIAG VDA

• Product Experience: History of product usage within the

company (Novelty of design, application or use case). Results
of already completed detection controls provide experience with
the design.
• Prevention Controls: Use of Best Practices for product design,
Design Rules, Company Standards, Lessons Learned, Industry
Standards, Material Specifications, Government Regulations
and effectiveness of prevention oriented analytical tools
including Computer Aided Engineering, Math Modeling,
Simulation Studies, Tolerance Stacks and Design Safety
Margins
• Note: O 10, 9, 8, 7 can drop based on product validation
activities.

DFMEA - AIAG VDA Training Course

Material 58
Confidential document of Innobest &
KGOC

Ranking Occurrence
number
• Used to Prioritize the causes/mechanisms
• Likelihood that the cause/mechanism will occur and result
in the failure mode
• Occurrence is defined based on the number of failures
which have happened/anticipated to happen during the
design life of the product.
• Occurrence number should be ranked in the following steps

– Get the data for the causes from the warranty/customer complaint
analysis reports. Ask the question “How many times this cause has
happened before” (Remember: During the Design life)
– If data is not available, Ask the question “How many times this
failure mode has happened before”

Identifying Current
Design controls
Type of Detail of Risk Examples
Controls Controls Level

A Cause Low Design Poka Yoke

Prevention

B Cause Detection Mod Proto verification

(before design
freeze)
C Failure Mode / High Validation on a part
Defect Detection (after design freeze)

DFMEA - AIAG VDA Training Course

Material 59
Confidential document of Innobest &
KGOC

Identifying Current
Design controls
• List the controls only if it is being currently
followed during the design and development
phase

• Not necessary that every cause should have a

Type ‘B’ or Type ‘A’ control

• Write controls clearly

• Use the current DVP for identification of controls

(as one of the input)

Identifying Current Design

controls - Examples

• Customer material specification

• Nut fitment test
• Torque test
• Using International Guidelines (Standard)
• Check the fitment in vehicle
• Actual Validation of part, Proto validation,
• Simulation Test
• FEA, Solid Modeling, etc
• Using GD & T Software
• Performing Alternate / reverse Calculation

DFMEA - AIAG VDA Training Course

Material 60
Confidential document of Innobest &
KGOC

Ranking the Detection

Ranking
• Steps in identification
– For the failure mode ask the question “If this failure mode will this
control detect it during testing”
– Take the causes for the next failure mode and continue

• Use existing data on detection for ranking and rate based on

consensus
• Do not bother about the occurrence number. Occurrence might be
low but still the control might not detect when it occurs
• If there are are many Type ‘B’ controls for the same cause or there
are many Type ‘A’ controls for the same failure mode rate the
detection number for every control
• Lower the number, better is the Detection

Detection Potential Ranking (D) for the validation of

Product Design – DFMEA AIAG VDA
Ability to Detect Detection Method Maturity D Opportunity for Corp or
Detection Product line
example

Test procedure yet to be developed. 10 Test method not

defined
Very Low
9 Pass-Fail, Test-
Test method not designed specifically to detect failure mode or cause. to- Fail,
Degradation
Testing

New test method; not proven. 8 Pass-Fail, Test-

to- Fail,
LOW Degradation
Testing

7 Pass-Fail
Testing
Proven test method for verification of functionality or validation of performance, quality, reliability and
durability; planned timing is later in the product development cycle such that test failures may result in
Moderate production delays for re-design and/or re-tooling 6 Test-to-Failure

5 Degradation
Testing

4 Pass-Fail
High Testing

Proven test method for verification of functionality or validation of performance, quality, reliability and 3 Test-to-Failure
durability; planned timing is sufficient to modify production tools before release for production.

High 2 Degradation
Testing

Very High Prior testing confirmed that failure mode or cause cannot occur, or detection methods proven to always 1 -----
detect the failure mode or failure cause.

DFMEA - AIAG VDA Training Course

Material 61
Confidential document of Innobest &
KGOC

Detection Ranking Mechanism

• Effectiveness of Type ‘A’ control is captured in the

occurrence number

• If the occurrence number is less the control is effective

• If the effectiveness of ‘Type – A’ control is not

validated, give higher ranking number (ex: 3) and observe
for the effectiveness before ranking as 1.

Action Priority Guide line – DFMEA AIAG VDA

DFMEA - AIAG VDA Training Course

Material 62
Confidential document of Innobest &
KGOC

Action Priority Guide line – DFMEA AIAG VDA

Recommended Actions -
Guide line
• Action Priority Categories:

1) High Priority due to High Risk Area

2) Medium Priority due to Medium Risk Area
3) Low Priority due to Low Risk Area

Priority: 1 H à L by taking optimized Actions or

H à M à L (step by step actions)
Priority: 2 M àL
Priority: 3 L à L by taking ultimate Actions

DFMEA - AIAG VDA Training Course

Material 63
Confidential document of Innobest &
KGOC

Identifying Actions
• Ask the following questions:
– Can we introduce a design control to prevent this
cause from happening during design
– Can we introduce a design control to detect this cause
if it happens to confirm the occurrence and initiate
corrective actions

• To Reduce Severity consider the following actions

– Change the design (Dimensions, tolerance, feature,
material)
– Will eliminate the failure modes

Identifying Actions
• To Reduce Occurrence numbers consider the actions
– Introduction of simulation techniques during design
– Finite element analysis during design
– Solid modelling techniques
– Computer aided design to eliminate errors

• To Reduce Detection numbers consider the actions

– Introduction of more verifications and checks for the
causes/failure modes
– Increase in the sample size during testing
– Checkpoints in Design reviews for better detection

DFMEA - AIAG VDA Training Course

Material 64
Confidential document of Innobest &
KGOC

Identifying Actions

• Write the responsibility and completion date for each of

the recommended actions

• Action Taken column is written only after the actions are

completed.

• Based on the actions completed and the effectiveness of

the actions the revised Severity, Occurrence and
Detection numbers are rated.

Identifying Actions
• Example of Actions:

- Revise Geometry / Spec / Tolerance

- Revise Material Spec
- Establish / Optimize Spec based on DOE
- Revise Test Plan
- Perform Computer Simulation
- Revise Hole dia to X dimn.
- Validate in Proto stage
- Follow International Guideline on Material spec

DFMEA - AIAG VDA Training Course

Material 65
Confidential document of Innobest &
KGOC

Deriving Design Review

checklist from DFMEA

• Address all the current Type ‘A’ controls in the Design

Review checklist

• Design reviews are done using this checklist to ensure that

the design is done following the prevention controls

• Helps to validate the prevention controls

Deriving DVP from

DFMEA
• Address all the current Type ‘B’ and Type ‘C’ controls in
the DVP.

• This will make the DVP complete and will list all the
checks/tests that needs to be done for the prototype part

• Ensure that all the Customer specified tests are addressed

in the DFMEA and DVP

• DVP is like Control Plan for Design

DFMEA - AIAG VDA Training Course

Material 66
Confidential document of Innobest &
KGOC

Responsibility & Stage

Matrix
Type of Start Complete Review & Initiate Prepare Customer Results
FMEA Update Review documen
& tation
Update
by
Concept Prog Definition Before detailed When R&D CFT End User, OEM Concept
stage design started concept incharge customer & FMEA
change Design format
function
Design During the Before release Every 3 Design CFT End User, OEM Design
detailed design of drg to months Incharge customer & FMEA
stage production Manufacturing format
process
Process During Before PPAP Every 3 Process CFT End User & Process
Manufacturing months Incharge subsequent FMEA
process design operation, OEM format
stage customer
Machine New Before the Every 3 Maintenance CFT Manufacturing Machiner
Machinery, machine is months incharge process y FMEA
TPM commissioned based on format
implementation break
down
data

DFMEA – Quick Summary

DFMEA - AIAG VDA Training Course

Material 67
Confidential document of Innobest &
KGOC

DFMEA – Quick Summary

• DFMEA – Start off:
- New Design – Full FMEA Preparation
- Existing Design in new application or Environment –
revise current model for the impact due to new
application or Environment
- Existing Design is changed for any reason – Revise
current model FMEA for impact and change due to
design change

DFMEA – Quick Summary

• Key Inputs:
- Product Structure Tree Diagram
- Boundary Diagram
- Interaction Matrix
- Regulatory requirement review
- Item Function Work Sheet
- P – Diagram
- VOC
- Earlier Experience

DFMEA - AIAG VDA Training Course

Material 68
Confidential document of Innobest &
KGOC

DFMEA – Quick Summary

• Team:
Experts from cross functions with defined Roles and
Responsibilities
• Function:
Primary & Secondary Functions considering Service,
Assembly and Manufacturing
• Failure Mode:
No Function, Partial / Over / Degraded Functions,
Intermittent Function, Unintended Functions – in
Measurable Terms

DFMEA – Quick Summary

• Effects:
Next Higher level Assembly, System, Vehicle level,
Customer, Regulations
• Severity:
Assign Ranking as per the Severity Table for each and
every effect addressed in Effects.
• Class:
Special Characteristics designation based on Safety /
Regulatory characteristics and Fit, Form, Function,
Appearance Characteristics (Sev Rank 9 & 10 = CC &
5 – 8 = SC). Various Organizations can have their own
classification (where Customer Specific requirements are
applicable accordingly to be followed)

DFMEA - AIAG VDA Training Course

Material 69
Confidential document of Innobest &
KGOC

DFMEA – Quick Summary

• Cause:
- Address all causes for every Failure Mode
- Address Root cause (s) clearly for all special
characteristics
- Caution: 1) Item Manufactured / Assembled
within as per spec
2) Design deficiency may cause Manufacturing /
Assembly variations
3) Interaction related causes may lead to failure

DFMEA – Quick Summary

• Occurrence:
- Assign ranking Cause wise as per Occurrence Table
- If in between the two values as per table, go for higher
ranking
- Assign Occ rank = 10 where the team cannot agree on
the occurrence / cannot estimate at this point of time
- Ranking 1 must be addressed where the situation only
like cannot happen / never happened

• Controls:
- Prevention of Cause of the Failure Mode, Detection of
Causes, Detection of Failure Mode to be addressed in
detail

DFMEA - AIAG VDA Training Course

Material 70
Confidential document of Innobest &
KGOC

DFMEA – Quick Summary

• Detection:
- Assign ranking as per the ranking table
- Assign 10 where there is no control at all
- Assign 1 only where “Poka Yoke” type control is there
and if Occurrence is 1

• RPN:
- There is no cut off value above which the action must be
taken or below which there is no need of action
- Min RPN is 1 and Max is 1000
- Two approaches in RPN (based on Failure Mode and
based on Causes)

DFMEA – Quick Summary

• Recommended Actions:

- Focus on Special Characteristics

(Look for Sev >= 5 or Sev * Occ >= 20 or High RPN)
- If there is no action planned, address as “None at present”
- Focus on “Poka Yoke” type of controls or other advanced
type action (rather than focusing on detection control)

DFMEA - AIAG VDA Training Course

Material 71
Confidential document of Innobest &
KGOC

DFMEA – Quick Summary

• Responsibility and Target completion date:
- Address the individual name (not generic)
responsible for this action
- Address the due date for action completion
(To be decided / On going – not to be written)
• Action completion & Revised RPN:
- Address the completed action in detail (not just
addressing “Completed”) and address RSEV (in case of
Design change / modification), ROCC (based on the data)
and RDET (based on improved controls)

Retention of FMEA

• What should be the retention period of FMEA?

• Concept FMEA?
• Design FMEA?
• Process FMEA?
• Machinery FMEA?

DFMEA - AIAG VDA Training Course

Material 72
Confidential document of Innobest &
KGOC

DFMEA – Final Presentations

by all the groups
Time Limit: 1 hour (max)

Thank You All

DFMEA - AIAG VDA Training Course

Material 73