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1940s the methodology of FMEA began to be perfected
By 1949 the success of FMEA lead the forces to adopting it as a military standard
By the 1960s the process was implemented by NASA
In the 1970s FMEA began to be used by the automotive industry
Failure Mode and Effects Analysis can be categorized based on the target part of the production.
(DFMEA) explores product malfunctions that are related to materials, form, interface components and engineering. These are failures that may affect factors such as product life cycle and safety.
The reason we use a DFMEA is because it is a good practice to identify risks early in the program. Identifying risk early for us provides the greatest opportunity to mitigate the issues prior to program launch.
(PFMEA) explores the faults related to the production processes of manufacturing and bringing all the industry components together.
(FFMEA) explores the faults in how the global system functions.
(SFMEA) involves the service design associated with the product.
There are five primary sections of the Design Failure Mode and Effects Analysis.
Each section has a distinct purpose and a different focus.
The DFMEA is completed in sections at different times within the design timeline of the project and not all at once.
Section 1 permits the Design Engineer to describe the item that is being analyzed.
The item can be the complete system, subsystem, or component.
The function describes what the item does and there may be many functions for any one item
Severity ranking is usually on a 1-10 scale
In Section 2, causes are defined and entered
The causes at a component level can be related to the material properties, geometry, dimensions, interfaces with other components, or other things which could inhibit the function. Causes at the system level should be cascaded into failure modes for a more detailed analysis
The occurrence ranking is an estimate on known occurrences. A value is assigned to this column typically, a 1 thru 10 scale is used
Section 3 lists the activities currently conducted to check the design’s safety and verify performance.
The tests and evaluations intended to prove that the design is capable are aligned to the causes and failure modes identified with the highest risks.
It is also very important to do all the testing in a logical order.
Section 4 starts with filling out the risk priority number (RPN). The RPN is the product of the three previously selected rankings. The formula is: Severity*Occurrence*Detection.
The objectives are as follows. Eliminate failure modes with a severity 9 or 10. Lower occurrence on causes by error proofing, reducing variation or mistake proofing. Lower detection on specific test improvements.
Section 5 is the action and results section. It is where you list the actions taken or reference the test reports that indicate the results.
It is important to note that acceptable risk is desirable and mitigation of high risk to low risk is the primary goal.
A re-ranked RPN is determined by recalculating the post-action severity, occurrence, and detection. The new RPN calculation should be compared with the original RPN. A reduction in this value is desirable.
DFMEA encourages the involvement of management and the assembly of a team with the appropriate skill level and experience to identify and address failures.
In the end, DFMEA is a low-cost way to make sure that a quality product is provided to the customer by proactively troubleshooting for issues from the developmental stages all the way through to its execution.