Why use it: The primary objective of a Design-FMEA is to uncover potential failures associated with the product that could cause:

• Product malfunctions.
• Shortened product life.
• Safety hazards while using the product.

Where to use it: Ideally, the DFMEA is begun at the earliest stages of concept development, and can then be used to help reduce down competing designs and to help generate new, more robust concepts.

When to use it: Design-FMEAs should be used throughout the design process, from preliminary design until the product goes into production.

How to use it: 10 Steps to Conduct a DFMEA:

1. Review the design — Use a blueprint or schematic of the design/product to identify each component and interface.
2. Brainstorm potential failure modes — Review existing documentation and data for clues.
3. List potential effects of failure — There may be more than one for each failure.
4. Assign Severity rankings — Based on the severity of the consequences of failure.
5. Assign Occurrence rankings — Based on how frequently the cause of the failure is likely to occur.
6. Assign Detection rankings — Based on the chances the failure will be detected prior to the customer finding it.
7. Calculate the RPN — Severity x Occurrence x Detection.
8. Develop the action plan — Define who will do what by when.
9. Take action — Implement the improvements identified by your DFMEA team.
10. Calculate the resulting RPN — Re-evaluate each of the potential failures once improvements have been made and determine their impact on the RPNs.

Name Format Preview (Click to enlarge)   DFMEA Template Microsoft Excel Format   DFMEA Checklist Microsoft Excel Format

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