Design Failure Mode and Effect Analysis (DFMEA)

PART CHARACTERISTICS OF FAILURE 1st RATING ACTION-STATUS 2nd RATING

Undesirable Customer
Follow-
Function/ Effects Recommended Decided Verification
No. Failure Mode Causes of Failure Testing Po S Pd RPN Responsible up Po S Pd RPN
Operation Effects of Failure on Action(s) Action(s) Signature
Date
part/syst./operation

Vehicle stoppage with or CAE Analysis / CAE to be performed to CAE analysis to

Eg. Should withstand the Deformation of BIW Weak design
without warning AET test
8 7 4 224
check the failure intensity be done
XXXX YYYY
82812119 load of both jack & CAE Analysis / CAE to be performed to CAE analysis to
Weak design Customer annoyance 3 3 4 36 XXXX YYYY
towing hook braces i.e.
Deformation of AET test check the failure intensity be done
(Outer 13.3Kg + 10Kg = Multiplate bracket
multiplate bracket Verification to be done in AET test results
storage box) 23.3Kgs material properties not Plate bend / cracked AET test 3 3 4 36 XXXX YYYY
AET test to be checked
capable

No: Function/ Generic mode at a Cause is for failure Effect is for failure List Recommended List the Enter who Enter when Enter the
Test to detect the failure modes &
Enter Part Operation: function level mode(s) mode(s) - Consequence of action(s) in order to action(s) that (not just the decided reference of
their causes NOTE:
No. Needs, wants, each failure mode eliminate/reduce failure have been department) action will the
requirements Failure Mode(s): Cause(s): risks and effects taken in the will be 2nd Rating is document
Testing(s):
Input(s): - No function Why would this happen Effect(s): Indicate for each failure effect, the project with complete the completed given only after that
Component Must be verb-noun- - Partial function or or how might this System/ Customer/ test form(s) where corresponding Recommended actions time schedule & action completion of presents the
list measurable, include too much function happen Environment failure modes can be detected may be directed to responsible decided (for follow- decided action(s) results of
special conditions or - Degraded function - Accidents eliminate the failure person up) the action &
constraints - Intermittent function One failure mode can - Legal non-compliance mode, reduce the signature of
All test methods shall relate to
- Unintended function have more than one - Repair occurrence or improve (One person the person
decided component or system
Method(s): cause, therefore, all - Image effect the detection of a responsible for responsible
tests during the development
Brainstorm, Do not list causes as independent causes of - Environment effect potential weakness by each decided for the
process
Functional analysis failure modes failure shall be given - Cost impact for customer an improved test action) action
separately These include road testing, method
Input(s): Associate each failure Avoid stating secondary prototype testing, rig testing, CAE
External functional with a function Method(s): effects of the failure simulations, TR test etc. Recommended actions HIGH Risk - If RPN >= 126
analysis, Previous Brainstorm, Cause and shall preferably RPN Threshold:
similar FMEAs, P- Question any function Effect Diagram, FTA Assumption(s): Purpose(s): focussed on eliminating Must have
diagram (FC table) which has only one Failure has already Forced to consider the planning of failure causes Recommended action
failure mode Input(s): occurred testing activities MEDIUM Risk - If RPN >= 37 & < 126
FTA, P-diagram (noise It is possible to have & for
Method(s): factors), Previous Method(s): Method(s): needed multiple actions Severity > 7 or
Brainstorm similar FMEAs, Field Brainstorm Rate each test method & consider for one risk High RPN (High risk)
failures (PROTUS, Fault LOW Risk - If RPN >= 1 & < 37
best (highest likelihood of
Input(s): frequency, QJ) Input(s): detecting) when more than 1 test Note(s):
Dysfunctional analysis, Dysfunctional analysis, method is stated Must have a
Previous similar FMEAs, Previous similar FMEAs, recommended action for NOTE:
Field failures (PROTUS, Field failures (PROTUS, Input(s): severity>7 or RPN is For Rating Probability of Occurrence (Po) / Severity (S) /
Fault frequency, QJ) Fault frequency, QJ) Verification plan considered to be a high
value
Probability of Detection (Pd) -
- Refer to Po / S / Pd rating standard tables

Date & Rev: Jan-2012 / 0.0