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to the
Training Seminar
on
DFMEA
Nathan & Nathan Consultants Pvt. Ltd. NNCPL/PPT/005 1.
DESIGN FMEA
Origin
FMEA
Common Definitions
Function :
Failure Mode:
Why FMEA ?
1. Essence is timeliness
2. Pro-Active rather than reactive
3. Before process failure mode occurs
Types of FMEA
Example :
SWITCH
ON/OFF COMPONENTS
C
A. HOUSING
B. BATTERIES (2 D CELL)
2 C. ON/OFF SWITCH
D. BULB ASSEMBLY
E. PLATE
BULB
ASSEMBLY
3 HOUSING
A
F. SPRING
D ASSEMBLY METHOD
1. SKIP FIT
4 1 4 2. RIVETS
3. THREAD
PLATE BATTERIES SPRING 4. SNAP FIT
E B F COMPRESSIVE FIT
+ 5 5
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POTENTIAL FAILURE MODE : Provide pleasing appearance Provide dimensional control for correct
1 Difficult to steer finishing frame geometry
POTENTIAL FAILURE MODE ( S )
2 difficult to pedal POTENTIAL FAILURE MODE ( S )
1 Finish deteriorates
FUNCTION 2 Paint chips 1 Length of frame mounting points too
1 provide reliable transportation long
2 Length of frame mounting points are too
POTENTIAL FAILURE MODE ( S ) Handle bar Assembly short
Example
Item function
• Occupant protection from
door hardware
Effect(s) of v
Failure
Review of the past things-gone-
wrong, concerns reports, and
group brainstorming is required.
Example
Cracked, Deformed, Loosened,
Oxidised, Leaking
s
• List the effects of failure mode on the
function, as perceived by the
customer.
• Describe the effects using the
terminology specified in Severity
rating table
• For each failure mode, more than one
effect can be listed
Example
- Noise
- Erratic Operation
- Poor Appearance
- Unstable
- Intermittent Operation
- Rough
- Inoperative
Cla Cause(s) /
Severity
ss Mechanism (s)
of Failure
O
Potential
c
Cause(s) /
Classification c
Mechanism
u
(s) of Failure
r
Process Proces
Control s Typical Failure causes may
Potential Cause(s) / Occ
s Control include, but not limited to
Mechanism (s) of Failure ur
Preventi s
on Detecti 1 Incorrect material
on specification
2 Inadequate design life
• Indication of Design assumption.
weakness, the consequence 3 Over stressing
of which is the failure mode. 4 Insufficient lubrication
• Describe the causes in such capability
a way that can be eliminated 5 Inadequate / improper
or controlled Maintenance instruction
• Typical cause include : 6 Incorrect algorithm
• Incorrect material 7 Improper software
specified specification / surface
• Inadequate Design life finish specification / travel
assumption specification
• Over-stressing 8 Excessive heat
• Insufficient Lubrication 9 Improper tolerance
Capability specified
Current Proces
Process s FOR
Occurrence Controls Control OCCURANCE
preventi s
on Detecti RANKING
on
• Estimate the probability of
occurrence on a 1-10 scale
• Rate against each causes
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• Use past data as a basis
(rejection %) for ranking
• Document the basis of
occurrence ranking
• For a new design, if there is no
previous experience, use team
judgement
Don’t consider failure-detecting
measures while giving ranking
(Prototype testing, etc.)
• Type of Controls
Level Type
• List the existing controls, which can detect the causes or failure
mode
If one column form is used then, the following prefixes should be
used
P – before each prevention control
D – before each Detection control
Detection RPN
ded Action
Actio O D R
Responsibility & Target Se
ns c e P
Completion Date v
Taken c t N
Action Results
Se Oc
Actions Taken Det RPN
v c
• While deciding the effect of the failure modes of the item, consider the next
sub-assembly stage onwards upto the level of end-user
• Give the occurrence rating, as far as possible, based on the existing data on
similar previous items
• While listing out the Causes/ mechanism of failure, consider the indication of
Design weakness, which leads to the failure mode.
2 HIGH REISK FAILURE MODES : The FMEA address all high risk failure modes
as identified by FMEA team , with executable action plans. All other failure
modes are considered .
8 TEAM : The right people participate as part of the FMEA team through
out the analysis and are adequately trained in FMEA methods