7 Steps Dfmea

The 7 Steps of a
DFMEA
Standard Training
18-May-2010
Copyright Autoliv Inc., All Rights Reserved
Table of Contents
Introduction
The 7 Steps of a Design FMEA
Step 1: Preparation Phase
Step 2: System Analysis/-Structure
Step 3: Function Analysis-/Structure
Step 4: Failure Mode Analysis
Step 5: Risk Assessment
Step 6: Optimization
Step 7: Maintenance @ daily product life
ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 2
Introduction - WHAT is a FMEA ?

FMEA = Failure Modes and Effects Analysis
A FMEA is a structured process to minimize risks when

doing multidisciplinary activities that allow AUTOLIV :
to meet customers expectations for new or changed
products / processes
to meet design, manufacturing, quality, timing, cost and
environmental goals
by avoiding potential failure modes.
Preparation Phase
System Analysis / Structure
Function Analysis / Structure
Failure Mode Analysis
Risk Assessment & Controls
FMEA
form
Optimization
Maintenance @ daily product life
Preparation Phase
FMEA
form
Optimization
1. Preparation Phase - Overview
Preparatory work
Team building
Definition of System Borders
1. Preparation Phase - Preparing Work

Collection of important documents (e.g. DGD,
specifications, drawings, system descriptions, etc.)

Risk Filter and / or Master FMEAs, if applicable
BOM and hardware (prototypes)
Preliminary [CC]/[SC] list or Master [CC]/[SC] list
Preliminary process flow chart
Lessons learned (AS 65)
Quality input, e.g. field-, COP-, internal-, supplier-, customer
data
Results from line design workshops

Clarification of questions related to resources (how
long, how often, etc.)
1. Preparation Phase - Team building

Risk analysis has to be done in a team only!
Product Engineering
Manufacturing Engineering
Production
Purchase
Quality
Involve, when applicable
Suppliers and customers
Testing / tool shop
Tool makers, etc.
All team members shall be trained in the FMEA methodology and
process.
1. Preparation Phase - Team building

FMEA team members definition depends on FMEA types:
Function
R&D
Design
X
Line Supplier
Process
Tool / machine
X
X
IE / PE
Quality
Tests
Production
C
X
Purchase
Maintenance
X : requested
C : optional
1. Preparation Phase - Scope Definition

Define the scope (Boundary of a FMEA for product and
process)
The scope defines what is included and what is excluded!
The following may assist to define the scope of a FMEA (see also Step
1 of a FMEA):
Function model,
Block (boundary) diagrams,
Parameter (P) diagrams,
Interface diagrams,
Process flow charts,
Interrelationship matrix,
Bill of Materials (BOM)
1. Preparation Phase - Scope Definition

Define the Customer
End user,
OEM Assembly or Manufacturing Plants,
Supply Chain Manufacturing,
Regulators,
Operators
Knowledge of these customers can help to define
functions, requirements and specifications more
robustly and can also help to determine the effects of
related failure modes.
Preparation Phase
FMEA
form
Optimization
Step 2: System analysis/-structure
Define System Borders

Which system are we going to analyse?
E.g. Restraint system, DAB system, etc.
NOTE:
NOTE:
systemcan
canbe
beconsidered
consideredto
tobe
bemade
madeup
upof
of
AAsystem
varioussub-systems
sub-systems//system
systemelements.
elements.
various
Define interfaces and their influence on the defined

system to analyse Block/Boundary Diagram
Towards other systems

e.g. Restraint system and car body system
e.g. between SW and DAB
E.g. between housing and cover

Example: PAB Module
Definition of System Borders = Boundary Diagram

Example: New R230 Ret
Definition of System Borders = Boundary Diagram
Minor Subsystems
Indirect interface with other subsystems

Rattling of buckle against seat cover
squeeking
Extraction / Retraction Interference
Bad anchorage point positions
Major Subsystems
Seat integration (e.g. SGS)
ECU-connection
.
Interface with the Environment

Minor Subsystems
PLP3 Takata Belt connection
Seat mounted buckle
.
Flammability
Twisted webbing
ESD
.

Boundary diagram...
is to define the extend of an FMEA
is a tool used to divide a complex system into more
manageable levels.
graphically illustrates the relationships among the various
subsystems, components,..
can be constructed to any level of detail.
is important to identify the major elements, understand how
they interact, and also understand how they interact with
the outside systems.

Airbag Module DFMEA
Top level
System
DFMEA
System
DFMEA
Subsystem
DFMEA
Components
Material req.
SB
Electrical
System
SW
Vehicle
System
Car body
System
Cover
Geometry req.
Material req.
PAB
Restraint
System
DFMEA
Characteristics
SAB
Container
Cushion
Geometry req.
Material req.
Geometry req.
DAB
Inflator
Material req.
Level 1
Level 2
Level 32
April, 2002
Level 4
Geometry req.
Level 5

Define system elements and system structure
Airbag Module DFMEA
DFMEA
Subsystem
DFMEA
Components
DFMEA
Characteristics
Geometry
Cover
Material
SAB
Geometry
Container
Material
Level 1
Level 2
Level 3
Level 4
Level 5
Consider three levels only!


DFMEA Vehicle
Top System
System
Subsystem
Component
Cover
Characteristic
Material
SAB
Restraint
System
...
Geometry
...
Vehicle
System
FE
FC
Failure effect
Failure mode
Failure causes
Level 1
Level 2
Level 3
Level 4
Level 5

DFMEA Restraint System
Top System
System
Subsystem
Component
Cover
SAB
Restraint
System
Vehicle
System
Level 1
Characteristic
Material
Geometry
IC
...
FE
FC
Failure effect
Failure mode
Failure causes
Level 2
Level 3
Level 4
Level 5

DFMEA Airbag Module
Top System
System
Subsystem
Component
Characteristic
Material
Cover
Vehicle
System
Level 1
Restraint System
Geometry
SAB
...
Level 2
FE
FC
Failure effect
Failure mode
Failure causes
Level 3
Level 4
Level 5

Definition of the considered level
In which level should we consider the failure,
the respective effects and causes?
FE
FC
Failure effect
Failure mode
Failure causes
Level 1
Level 2
Level 3
FE
FC
Failure effect
Failure mode
Failure causes
FE
FU
Failure effects
Failure mode
Failure causes
FE
FU
Failure effects
Failure mode
Failure causes
DFMEA
Airbag Module
Level 4
Level 5
DFMEA
Vehicle
DFMEA
Restraint System
This picture means:

e.g. The failure mode of the Vehicle DFMEA becomes
the failure effect of the Restraint System DFMEA.

FMEA & Requirement V-Cascade
Voice of the customer / market
Vehicle
Requirements
Concept
FMEA
System
Specifications
System
FMEA
Sub-System
FMEA
Component
Specifications
Component
FMEA
Risk
strategy
CC/S
C
Sub-System
FMEA
CC/S
C
Component
FMEA
Design Verification
Vehicle Design
Verification
Risk
Management
System Design
Verification (DVP&R)
Sub-System Design
Sub-System
FMEA
Risk
Management
Component
FMEA
CC/SC
Component Design
Prototype
Control plan
Preparation Phase
FMEA
form
Optimization
Step 3: Function analysis-/structure

General
Based on the defined system structure:
Enter the function of the item which is necessary to
meet the design intent based on customer
requirements.
NOTE:
NOTE:
Oneitem/element
item/elementcan
canhave
havemore
morethan
thanone
one
One
function.
function.

Standardized Life Time Cycle
7 levels (+ 1 optional level) defined
Standardized Life Time Cycle has to be applied until component level
ALV assembly
Transportation and storage
Customer assembly
Normal use of vehicle
Crash
After Sales
Recycling
Link to page FMEA Template
Master function
. Optional (e.g. Post-Crash)
NOTE:
NOTE:
Afterfunction
functionanalysis,
analysis,work
workwith
withthe
theFMEA
FMEAsheet
sheetcan
canbe
be
After
started.
started.
Preparation Phase
FMEA
form
Optimization
ALV FMEA Template

ALV FMEA Template please see PLM: E606648
If FMEA template and software is available, minimum requirement

is shown in AS 104 Excel Template = ALV Template!
Within the ALV Template also the AIAG 4th ed. (QS 9000) Template is
available.
Further different templates are existing
VDA, customer specific, IQ-FMEA (APIS), AQuA Pro, .
ALV FMEA Template
Note: The ALV template can be applied for DFMEA AND PFMEA.
ALV FMEA Template

Note:
Severity of 9 or 10 indicates a potential Critical
Characteristic [pCC]
Severity of 7 or 8 indicates a potential Significant
Characteristic [pSC]
Note:
A potential Critical Characteristic [pCC] or a potential
Significant Characteristic [pSC] can become a [CC] or a
[SC] after application of the determination process
(please see next page)
ALV FMEA Template

1
For [CC]/[SC] marking use the following

function in the ALV FMEA Template:
1) Go to the column pSC/pCC to SC/CC
2) Choose X
3) In the Classification column [CC] or

[SC] will be shown
ALV FMEA Template

Function Pareto Synthesis
The Pareto Synthesis for RPN optimization is shown automatically!
! Within the original FMEA Excel Sheet please see the flag Synthesis!
Further FMEA Templates

E.g. IQ RM Software
System Structure
Function / Failure Mode

Analysis
Further FMEA Templates

e.g. AQuA PRO Software

Working with the ALV FMEA Template
Item or Master Function
List the respective Master Function out of the

Standardized Life Time Cycle (see page 28)
Click here to go back to the page

Standardized Life Time Cycle

Function
List all functions in a verb / noun /

measureable format

Requirement
List all requirements

List the acceptance criterion
Preparation Phase
FMEA
form
Optimization

General
Potential failure mode is defined as the manner in which a item
(e.g.
component) could potentially fail to meet the intended
function.
Potential failure mode(s) are associated with the functions.
Potential failure modes should be described in technical terms.
NOTE:
NOTE:
Eachfunction
functionmay
mayhave
havemultiple
multiplefailure
failuremodes.
modes.
Each
Theassuption
assuptionisismade
madethat
thatthe
thefailure
failurecould
couldoccur,
occur,but
butmay
may
The
notnecessarily
necessarilyoccur
occur->
->use
useof
ofthe
theword
wordpotential.
potential.
not

Categories of Failure Modes:
No function / Lost of function
Partial / hyper function / degraded over time
Degraded mode: too early, too late, decline of
outputs, wear, fatigue,
Unintended Function
Intermittent Function

Failure mode is linked to product function
Failure modes
Mode meaning
Lost
Lost of function
No
No function
Example
Design
C ra
sh
Function : Ensure the mechanical connection

between the clamp and cable
Mode: Lost
Degraded
Too early, too late
Unexpected
Inadvertent deployment
Permanent
Unexpected function,
e.g. horn function
Meaning : Stop to ensure (at one moment) the link

between the clamp and cable
Mode: No
Meaning : Doesnt ensure the link (at any moment) the
link between the clamp and cable
Potential Failure Mode
List each potential Failure Mode

associated with the particular
function.
Preparation Phase
FMEA
form
Optimization

General
Potential Effect of Failure is defined as the effect of the Failure
Mode, as perceived by the customer

Potential Effects of Failure are what the customers might notice or
experience in each phase of the products life time (operator,
customer operator, motorist, )
NOTE:
NOTE:
Customermay
maybe
bean
aninternal
internalcustomer
customeras
aswell
well
Customer
asthe
theultimate
ultimateend
enduser.
user.
as
Failure effect
is linked
to the function
(customer need)
Effect
Severity
Design
Function: Ensure mechanical connection between
tongue and frame seat.
No
occupant
protection
Sub-Function:
Ensure mechanical connection between
clamp and cable
Mode:
Lost
Meaning: the link between clamp and cable is
not ensured (for a moment)
10
Severity
quotation
S based
on standard
ranking
(QS 9000 /
ALV FMEA)
Potential Effect(s) of Failure
Describe final impact on the user in

each phase of products life time

Severity (S)
Severity is the value associated with the most
serious effect for a given failure mode.
Severity should be estimated using the ALV
Ranking Table
NOTE:
NOTE:
reductionin
inSeverity
Severityranking
rankingcan
canbe
be
AAreduction
effectedonly
onlythrough
throughaadesign
design change.
change.
effected
Severity (S)
Rank the impact of the failure mode for

the customer
Rating from 1 to 10 with 10 being the
most severe

Classification Column
To highlight high-priority failures modes and their
associated causes.
To classify any special product characteristic, e.g.
potential critical or potential significant, critical or
significant that may require additional design or process
controls.
NOTE:
NOTE:
ALVMarking:
Marking:
ALV
[CC],[SC],
[SC],[pCC],
[pCC],[pSC]
[pSC]only
only
[CC],

Require special controls
Capability
Poka Yoke
100% Inspection
Or other methods
which are appropriate
Classification (C)
Identify any special characteristics

that may require special controls
Marking: [CC], [SC], [pCC], [pSC]

Potential Causes of Failure Mode
Identification of all potential causes of the failure modes
is the key for a subsequent analysis.
Each failure mode can have several potential causes.
NOTE:
NOTE:
productor
orprocess
processcan
canhave
haveseveral
severalfailure
failure
AAproduct
modeswhich
whichare
arecorrelated
correlatedto
toeach
eachother
otherbecause
because
modes
commonfailure
failuremechanism
mechanismisisbehind
behindthem.
them.
aacommon

Potential Causes of Failure Mode
Design :
The identification of causes can be carried out with the help of the
functional analysis (if available)
Clamp
Ensure the link
between the
clamp and cable
Cable Clamp / Cable
Analyse component (interface) by

component (interface) for each
potential design causes that could
lead to the failure mode.
Potential Cause of Failure
List any possible potential cause of

the failure mode
The identification of causes can be
carried out by answering: Why
does this failure mode appear?
Causes
Design
Function: Ensure mechanical connection between
tongue and frame seat.
Sub-Function:
Ensure mechanical connection
between clamp and cable
Mode:
Lost
Meaning: the link between clamp and
not ensured (from a moment)
cable is
Internal clamp
diameter /
external cable
diameter ratio
incorrectly
defined (clamp
Occurrence
diameter definition
doesnt fit on cable
diameter)
Occurrence
rating O
based on
standard
ranking
(QS 9000 /
ALV FMEA)
O - Occurence
Occurence is the likelihood that a specifc cause/

mechanism will occur during the design life.
A reduction of Occurence can only be achived by a
design od process change.
Occurence should be estimated using the ALV
Rating Table
Occurence
Occurrence is the likelihood that a

specific cause/mechanism will occur
resulting in the failure mode within the
design life
Estimate the likelihood of Occurrence
on a 1 to 10 scale.

Current Design Controls
There are two types of Current Design Controls
Preventive controls reduce the likelihood that a failure
mode/cause will occur, e.g. material definition, folding
definition
Detective controls help to detect problems, e.g. functional
testing
Current Design Controls

There are three types of Design Controls/
features
1. Prevent the cause / mechanism or failure
mode / effect from occurring or reduce their
rate of Occurrence
2. Detect the cause / mechanism and lead to
corrective actions and
3. Detect the failure mode

D
- Detection
What kind of opportunities do I have to find the failure?
What kind of checking methods do I use?
Rating e.g.
1 No possibility to produce NOK parts. The failure is
detected by the process.
10 Finding the failure and NOK parts is impossible.

D
- Detection
Detection is the rank associated with the best

detection control (listed in the Current Control
Detection column)
Detection should be estimated using the ALV Rating
Table
Detection (D)
Detection is the rank associated

with the best detection control
listed in the Current Design
Control Detection column

Risk Priority Number (RPN)
The RPN calculation allows, based on the experience of team
members, to assess the risk related to failure mode effects and
and their respective control based on a triple ranking
RPN = (Risk Priority number)

Severity x Occurrence x Detection
Minimum RPN=1 (S=1, O=1, D=1)

Maximum RPN=1000 (S=10, O=10, D=10)
Risk Priority Number (RPN)

(S) x (O) X (D) = RPN
Preparation Phase
FMEA
form
Optimization
After RPN is calculated, actions shall be prioritized:
1) Create or check Pareto Synthesis*
2) Reduce high RPNs
3) Prioritize due to
Severity
Occurrence
Detection
NOTE:
NOTE:
NoRPN
RPNlimit
limitexists!
exists!
No
Thereduction
reductionof
ofRPN
RPNisispart
partof
ofthe
theALV
ALVContinuous
Continuous
The
ImprovementProcess
Process
Improvement
(* Pareto Synthesis is integrated in the ALV FMEA template see flag Synthesis)
How to reduce potential risk ?
Reduce
"D" :
To reinforce the detection (verifications and

validations necessary to reduce the risk)
Reduce "O" : To modify design / process in order to

reduce likelihood of cause appearance
Reduce "S" :
system
To make an effect less important on the
For a same / similar design, Severity doesn't change!
Recommended Action
The intend of any recommended

action is to reduce rankings!
Responsibility and Target Completion Date
Enter the name of organization and individual

responsible for each recommend action and the
target completion date.
Actions Taken
After the action has been implemented, enter a

brief description of the actual action and effective
date, and if possibly connect to report numbers
etc.
NEW RPN
After the action has been implemented,

calculate a NEW RPN number!
Actions Results New RPN
It is necessary to distinguish corrective
actions regarding their chronology
(Reduce the risk during
product development)
Take only into account

what it is really carried out
and not what it is planed!
Effects
S Causes
Corrective Actions
640
Action 1
10
480
Detection
Detection 1
Effect 1
10
Cause 1
Effect 1
10
Cause 1
Action 1
480
Action 2
10
200
Effect 1
10
Cause 1
Action 2
200
Action 3
10
40
Preparation Phase
FMEA
form
Optimization
Step 7: Maintenance @ daily product life

! NOTE !
Update the FMEA always according to new information.
Information from customer concerns (Problem solving,
Lessons Learned), technical innovation, supplier change,
material change, new production site, ...
At least an update of the FMEA has to be done in each

APDS phase (before TG). The FMEA document has to
be released in the PLM System.
Start the optimization cycle again from the beginning!

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The 7 Steps of a

Copyright Autoliv Inc., All Rights Reserved

Copyright Autoliv Inc., All Rights Reserved

Introduction - WHAT is a FMEA ?

A FMEA is a structured process to minimize risks when

by avoiding potential failure modes.

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 3

Copyright Autoliv Inc., All Rights Reserved

The 7 Steps of a Design FMEA

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 4

Copyright Autoliv Inc., All Rights Reserved

The 7 Steps of a Design FMEA

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 5

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Overview

Definition of System Borders

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 6

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Preparing Work

specifications, drawings, system descriptions, etc.)

Results from line design workshops

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Team building

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 8

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Team building

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Scope Definition

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 10

Copyright Autoliv Inc., All Rights Reserved

1. Preparation Phase - Scope Definition

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 11

Copyright Autoliv Inc., All Rights Reserved

The 7 Steps of a Design FMEA

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 12

Copyright Autoliv Inc., All Rights Reserved

Step 2: System analysis/-structure

Define System Borders

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 13

Copyright Autoliv Inc., All Rights Reserved

Step 2: System analysis/-structure

Define interfaces and their influence on the defined

Towards other systems

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 14

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Step 2: System analysis/-structure

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 15

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Step 2: System analysis/-structure

Indirect interface with other subsystems

Interface with the Environment

Step 2: System analysis/-structure

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 17

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Step 2: System analysis/-structure

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 18

Step 2: System analysis/-structure

Consider three levels only!

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Step 2: System analysis/-structure

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 20

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Step 2: System analysis/-structure

ALV Training - 7 Steps DFMEA Training / 18-May-2010 - 21