A deductive, practical and useful way to apply Failure Modes & Effects Analysis to product designs

1. D F M E A World Class Results

7. The Chain Of Verification Design FMEA DFM/ DFA Studies Generate Design Verification Plan Generate Drawings & Specifications DV: FEA, CAE & Analysis Construct Prototypes w/ Control Plan DV: Physical Testing DVP&R Sign-Off Approved Quote

9. DFMEA Process 1 Define Project 2 Analyze Product Functions 3 Deduce Failure Modes 4 Brainstorm Effects & Rate Severity 5 Brainstorm Causes & Rate Occurrence 6 Develop Controls & Rate Detection 7 RPN & Action Planning 8 Measure, Track & Drive Action Project Requirements Cross Functional Team FMEA Knowledge 9 Reduce Risk Improve Customer Satisfaction Boundary & Function Diagrams Failure Mode Worksheet Main Worksheet Main Worksheet Main Worksheet Main Worksheet Main Worksheet SC/CC LIST Block & P-Diagrams, Interface Matrix Main Worksheet Specification Worksheet

11. Mechanical Pencil Example 0.7 mm Eraser Lead Clip Tube Assembly Barrel EAT AT JOE’S

13. 1 Define Project Project Assignment Development Team FMEA Knowledge Block Diagram Pencil Assembly Barrel Assembly Lead Tube Assembly Eraser Clip Main Tube Eraser Cup Spring Feed Assembly Spring Tube Spring Flexible Tip Tube System Subsystems Components Parts

17. 2 Analyze Product Functions Interface Matrix

18. Pencil Matrix Setup: Identity Cells Mirror Cells INTERNAL From P-Diagram (Important Noise Factors) Each cell identifies serial or direct relationships -Hip Bone to Thigh Bone to Knee Bone NOT Hip to Knee UNLESS there is a direct physical or electrical connection, or an exchange of information or material

19. Pencil Functions

20. 4 3 2 1 FUNCTIONAL SPECIFICATIONS: Bi-Lateral Or Unilateral Tolerance/Required Properties Function Description: Active Verb/Measurable Noun Date Page Of Project: D-FMEA: Product Specification Worksheet 2 Analyze Product Functions Engineering Specifications

23. The Failure Mode Worksheet Verb-Noun Stan- dard Mode 1 Mode 2 Mode 3 x x x x

24. 3 Deduce Failure Modes Failure Mode W/S

25. Mode From Step 3 Effect From Step 4 6 Cause From Step 5 3 3 Action Against Cause Physical Test For Effect 7 RPN & Action Planning Main W/S 4 Brainstorm Effects & Rate Severity Main W/S 5 Brainstorm Causes & Rate Occurrence Main W/S 6 Develop Controls & Rate Detection Main W/S 8 Measure, Track & Drive Action Main W/S

27. Cause & Effect Relationships… FUNCTION FAILURE MODE (ERROR STATE) Cause Cause Cause Cause Cause Effect Effect Effect Effect Effect

34. Controls & Detection 1 Define Project 2 Analyze Product Functions 3 Deduce Failure Modes 4 Brainstorm Effects & Rate Severity 5 Brainstorm Causes & Rate Occurrence 6 Develop Controls & Rate Detection 7 RPN & Action Planning 8 Measure, Track & Drive Action Project Requirements Cross Functional Team FMEA Knowledge 9 Reduce Risk Improve Customer Satisfaction Interface Matrix Function Diagram Failure Mode Worksheet Main Worksheet Main Worksheet Main Worksheet Main Worksheet Main Worksheet SC/CC LIST Block & P-Diagrams Main Worksheet Functions & Requirements