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Design
Design Failure
Failure Modes
Modes and
and Effects
Effects Analysis
Analysis (Information
(Information Sheet)
Sheet)

DFMEA Number:

Design Name:

Design Responsibility:

Prepared By:

Affected Product(s):

DFMEA Target Date:

DFMEA Actual Release Date:

DFMEA Revision Date:

Core Team Members:

Participants:
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TEAM CHARTER - DESIGN FAILURE MODE & EFFECT ANALYSIS

Contact Number(s) Attendance (Fill as appropriate)

Name of the Personnel
Sl.No. Function / Process
(Append photograph)
Mobile Email Adress Work Extension Review 01 Review 02 Review 03 Review 04 Review 05

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Note

01 A CFT comprising of the following personnel, is recommended for DFMEA preparation & review

- Design function - Customer's Representative

- Quality function - Supplier's Representative

- Manufacturing function - Field / Subject matter experts

- Sales / Marketing function - Service / Field Personnel

- Lab / Testing function - Others, as necessary

 FUNCTIONAL REQUIREMENT

Sl. No. Requirements Description of the requirements Specific references to Standards, if any

B Government Regulations

C Corporate Guidelines / Policies

D Past Experience (Prepare Occurrence Matrix)

E Bench marking

F Other relevant information, if any

* Attach separate sheets, if necessary

System Subsystem Components Sub-components
 System Subsystem Components Sub-components
Spool
Terminal Pins
Spool Assembly Winding Wire
Electrical Wire
Solenoid
Grommet
Energiser
- Encapsulation
Fasteners
Solenoid Valve Anker
Seal
Anker Assembly
Inner Spring
Operator Assembly Outer Spring
Einsatz
Guide Assembly Guide
O Ring
Orifice
- -
Valve Body
 ITEM FUNCTION WORKSHEET

The Item Function worksheet is used to determine the scope and prioritise, organise the work efforts involved in conducting a Design
FMEA. Based on the rankings the Team can prioritise the focus.

Description: (Of System / Sub System / Component / Sub-Component)

List all the functions and separate them from the specifications.

Determine the hierarchy of the function and assign an initial ranking.

Function Description Specification

Ranking
(In Verb - Noun) How Much When
 CAUSE & EFFECT DIAGRAM - EXERCISE

NOTE:
1. Identify and define the Effect in Quantitative terms. 3. Identify the causes influencing the factors 5. Use Brain Storming technique to generate ideas / causes.

2. Fill in the Effect box and fill the main categories. 4. Add detailed levels and analyse the diagram 6. Use Why Why analysis (5 Why's) for root cause analysis.
 EFFECTS LIST FOR DFMEA
System / Component:

Team charter (Attach / hyperlink)

Function description
Date of Preparation

Effects (as applicable)

Failure Mode
Dealer End User Legal Vehicle Govt. Regulation End User

No Function

Over Function

Under Function

Reverse Function

Intermittend Function

Degraded Function

How to fill this Matrix?

01. First list all the Failure Modes in the respective Column,

02. Then assess the effect of each one on the Part, next higher Assembly, System, Government Regulations, etc.
03. This matrix thus becomes a ready reference for furnishing the ‘Potential Effects of the Failure’ in the FMEA form and also becomes useful during FMEAs at other various levels.
 Neighbouring - 1

Neighbouring - 2
Neighbouring - 4
System
Neighbouring - 3
Neighbouring - 5

Neighbouring - 6

Neighbouring - 7

Step 1 Draw the diagram explaining are interactions of the system/component under consideration to its neighbouring systems.
This will help the team to come to the common understanding about the system./component working w.r.t. higher level system.
This also helps in defining the controls properly.

Step 2 Draw system connections to all its neghbouring systems. These connections/interactions could be,
Assembly
Mass Transfer
Energy Transfer (Power)
Heat Transfer
Electrical
Define any other, if required.
 INTERFACE MATRIX (Sample) P +2

A B Design Controls

P -2
A B Design Controls

P E P Physically touching

I M E Energy transfer

I Information exchange

M Material exchange

Numbers in each corner represent the above interface types, with values denoting the following:

+2 Interaction is necessary for function

+1 Interaction is beneficial, but not absolutely necessary for functionality

0 Interaction does not affect functionality

-1 Interaction causes negative effects but does not prevent functionality

-2 Interaction must be prevented to achieve functionality

Objective a. A system interface matrix illustrates relationships between the subsystems, assemblies, subassemblies, and
components within the object as well as the interfaces with the neighboring systems and environments.
b. A system interface matrix documents the details, such as types of interfaces, strength/importance of interface,
potential effect of interface, and etc. It is a recommended robustness tool that acts as an input to Design FMEA.

c. It is important to note that not addressing interactions at this point can lead to potential warranty and recall
issues. Therefore, the interface matrix should always be used, especially on new designs
 I +2 E +2 M +2

A B Design Controls A B Design Controls A B

I -2 E -2 M -2
A B Design Controls A B Design Controls A B
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Design Controls

2
Design Controls
 P - DIAGRAM

Piece to Piece Variation (MFG Variation) Neighbouring Sub-systems ( Component to Component Interaction)

Environmental (Component to Env Interaction) Changes over time / Mileage (Wear/Time) Customer usage & Duty cycle

NOISE FACTORS

SIGNAL FACTOR (M) RESPONSE (Y)

ERROR STATES

CONTROL FACTORS
 OCCURRENCE RANKING MATRIX

Product / Aggregate Sample Sheet

Total quantity prouduced (Data period - 12 / 24 / 36 MIS)

Defects / Concern Total Rejected / Reworked Rejection / Rework / 1000 pieces Occurance Ranking*

INTERNAL FAILURE DATA

Source Inspection

Defect A

Defect B

Defect C

Defect D

Pre delivery inspection

Concern A

Concern B
Concern C

Concern D

Inspection XXX

Concern A

Concern B

Concern C

Concern D

Testing XXX

Concern A

Concern B
Concern C

Concern D

EXTERNAL FAILURE DATA

WARRANTY

Concern A

Concern B

Concern C

Concern D

DEALER CONCERNS
Concern A

Concern B

Concern C

Concern D

INDUSTRY SURVEY RESULTS

Concern A

Concern B

Concern C

Concern D

Add additional Internal & External failure data as appropriate to your Product

Characteristics Cpk / Cmk Occurance Ranking

* From FMEA Ranking table

 Potential
FMEA No.: __________________
Failure Mode Effects Analysis
( Design FMEA ) Page :___________ of ________
ITEM : DESIGN RESPONSIBILITY : Prepared By. : ________________________________________

MODEL YEAR(s) / VEHICLE(s) : KEY DATE : _______________________________________________________ FMEA date ( Orig. ) __________________ ( Rev.) ___________

Item Function Worksheet Item Function Worksheet Effect List Effect List

O Responsibility &
Potential Cause(s)/Mechanism(s) of Current Design Current Design
Potential Failure Mode Potential Effect(s) of Failures s c c D R S Recommended Action(s) Target Action Results
e l Failures Control Prevention c Control Detection e P O Completion Date
ITEM Function v a u t N D
s r e S O D R
s e c Action Taken e c e P
v c t N

Shaft
 LIST OF POTENTIAL CRITICAL & SIGNIFICANT CHARACTERISTICS

Sl.No. Characteristic CC/SC Remarks

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 DESIGN VERIFICATION PLAN & REPORT

Component / Assembly DVP No: Report No:

Application Plan Date: Report Date:

Source of material Concurrence: Department:

Plan Originator: Manager - Approval: Reporting Engineering:

Sample Timing Samples tested

Target Test Notes /
Item No. Procedure or Standard Test Description Acceptance Criteria Test Stage Actual results
Requirements Responsibility Observations
Quantity Type Start End Quantity Phase

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 ACTION PLAN FOR LIST OF RECOMMENDED ACTIONS IN DFMEA

How many How to do

Sl.No. What Where Which (m/c) Why do (Cause) Who When
How much (Method)

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