Why we go for DFMEA ?

Design Failure Mode Effect

Analysis

DFMEA
Analyses product design before release
to production, with a focus on product
function.
Analyses systems and subsystems in
early concept and design stages

TYPES OF DFMEA
SYSTEM

FMEA
- Chassis system
- Engine system
- Transmission

COMPONENT FMEA
- Piston
- Crankshaft

Responsibility and scope of

DFMEA
The DFMEA is a team
function
All team members must participate
Multi-disciplinary expertise and input is beneficial
Input from all engineering fields is desirable
Representatives from all areas (not just technical
disciplines) are generally included as team
members
The DFMEA is not a one meeting activity
The DFMEA will be refined and evolve with the
product
Numerous revisions are required to obtain the full
benefit of the DFMEA
The DFMEA must include all systems, sub-systems
and components in the product design

Steps in DFMEA

System
Subsystem
Component
Model Year/Vehicle(s):
Core Team:

Potential
Failure Mode and Effects
Analysis (Design FMEA)
Design Responsibility
Key Date:

C Potential
O Current
Potential Potential
L
Design
Failure Effect(s) of S A
C
Cause(s)/ C Controls
Mode
Failure E SMechanism(s) U
Of Failure
Function
R Prevention
VS

Item

FMEA Number:
Page 1 or 1
Prepared by:
FMEA Date (Orig.):

Responsibil Action Results

Current D
E
Design
R. Recommend
& Target Actions S O D R.
ed
Controls T P.
Action(s)
E N.
ity
Taken E C E P.
Detection C
Completion
Date
V C T N.

DFMEA Form

Failure Categories

Failure Categories
Reliability
Independent
Catastrophic Inherent
Weakness
Complete
Intermitte
Critical
nt
Degradation
Major

Dependent
Minor
Gradual
Misuse
Nonrelevant

Partial
Primary
Random
Relevant
Secondary
Sudden
Wear-out

Severity, Occurrence &

Detection
Severity
Importance of the effect on
customer requirements
Occurrence
Frequency with which a given cause
occurs and creates failure modes
Detection
The ability of the current control scheme
to detect or prevent a given cause

Occurrence (O) Table

Probability of Failure
Very High : Persistent
failures

Possible Failure Rates

> 100 per thousand vehicles/ items
50per thousand vehicles/ items

Ranking
10
9

High : Frequent failures

20 per thousand vehicles/ items

10 per thousand vehicles/ items

5 per thousand vehicles/ items

2 per thousand vehicles/ items

1 per thousand vehicles/ items

Low : Relatively few

failures

0.5 per thousand vehicles/ items

0.1 per thousand vehicles/ items

Remote : Failure is
unlikely

< 0.010 per thousand vehicles/ items

Moderate : Occasional
failures

Severity (S) Table

Effect
Hazardous
without
warning
Hazardous
with warning
Very High
High
Moderate
Low
Very Low
Minor
Very Minor
None

Criteria : severity of Effect

Very high severity ranking when a potential failure mode affects safe
vehicle operation and/or involves noncompliance with government
regulation without warning.
Very high severity ranking when a potential failure mode affects
safe vehicle operation and/or involves noncompliance with
government regulation with warning.
Vehicle/ item inoperable (loss of primary function).
Vehicle/ item operable but at reduced level of performance.
Customer very dissatisfied.
Vehicle/ item operable, but Comfort/ Convenience item(s)
inoperable. Customer dissatisfied.
Vehicle/ item operable, but Comfort/ convenience item(s) operable
at a reduced level of performance. Customer somewhat dissatisfied.
Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed
by most customers (greater than 75%).
Fit & Finish/ Squeak & Rattle item does not conform. Defect noticed
by 50% of customers.
Fit & Finish/ Squeak & rattle item does not conform. Defect noticed
by discriminating customer (less than 25%).
No discernible effect.

Ranking
10

8
7
6
5
4
3
2
1

Detection (D) Table

Detection
Absolute
Uncertainty

Criteria : Likelihood of Detection by Design Control

Design control will not and/or can not detect a potential cause/
mechanism an subsequent failure mode; or there is no Design
control

Ranking
10

Very Remote

Very remote chance the Design control will detect a potential

cause/ mechanism and subsequent failure mode.
Remote chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Very low chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Low chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Moderate chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Moderate high chance the Design control will detect a potential
cause/ mechanism and subsequent failure mode.
High chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Very high chance the Design control will detect a potential cause/
mechanism and subsequent failure mode.
Design control will almost certainly detect a potential cause/
mechanism an subsequent failure mode.

Remote
Very Low
Low
Moderate
Moderate High
High
Very High
Almost Certain

8
7
6
5
4
3
2
1

Risk Priority Number (RPN)

RPN is the product of the severity,
occurrence, and detection scores.

Severity

Occurrence

Detection

RPN

Action
Recommend Action, wherever RPN is
high through
- Design Controls
- Design changes
- Process changes
- Special controls changes to
standards/procedures/guidelines

Decide
Responsibilities
Decide Target date of
completion.

What Next?
Repeat: undertake the next revision of the DFMEA
The DFMEA is an evolving document!
Revise the DFMEA frequently & keep on reducing
RPN! Diligence will eliminate design risk!
Include documentation of your results!

WEIGHT AND COST

ESTIMATION
Kerb weight
= 198.3
2016
kg
Laden weight = 258.3
kg
4%

2%

46

11%

Electrical
equiment
Power Train
Steering
Suspension

14%
2%

WEIGHT
Kerb weight =
161.1 kg
Laden weight =
228 kg
7.3; 3% 8; 4%
32; 14%
22; 10%
33; 15%
11; 5%
48; 21%
62; 28%

Total cost =
3,54,200

Brakes

Frame

18%

1
1

Transmission
5,000 15,000 2,000
40,000
38,000
80,000
8,000
28,200
120,000
18,000

Driver and
Seat

2017

Wheels & tyres

Brakes
Steering
Suspension

Suspension
Brakes

Spares

COST

Seat

Total cost = 4,25,599

125789; 30%40000; 9%

20000;
2000; 5%
0%

32437; 8%

36000; 8%
24786; 6%
8000; 2%
51200; 12%
85387; 20%

Miscellaneous
Driver & seat

WEIGHT

Steering

Aesthatics

Engine & Power

train
Roll Cage

Roll cage
matrerials

Wheels

Wheels and
Hub
Miscalleneous

Engine service

COST

Engine
Roll Cage
Wheels & tyres
Brakes
Steering
Suspension
aesthatics
seat
spares
transmission

PROJECT
PLAN

1
2