A DFMEA is a design tool used to systematically list potential failure modes of a design. It aims to increase design robustness by involving a team to identify failures, satisfy customers, and incorporate checkpoints and reviews with experts and customers. The process involves a DFMEA expert developing the analysis, getting senior reviews, and implementing agreed changes from customer reviews to iteratively improve the design.

1. DFMEA
Definitions & Methods

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What is a DFMEA ?
FMEA stands for Failure Mode and Effect Analysis
A DFMEA is the FMEA done at the Design stage
A DFMEA is:
a design tool
a team effort
a living document

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What are a DFMEA’s goals ?
To increase the robustness of a design by
systematically listing its potential failure modes
Satisfy its customerS who can be:
the OEM
the end customer (the driver)
the process team
the manufacturing team
…

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How do we proceed ?
1) A TE DFMEA expert develops the DFMEA.
2) His work is reviewed by a senior TE engineer before
each checkpoint.
3) This work is reviewed and discussed by the
customer DFMEA team during the checkpoints.
4) The TE DFMEA expert implement the agreed
corrections and carry on the development
5) Back to point 2)

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Some examples of TE experience in DFMEA
Integrated starter alternator controller
Starter alternator power module
Active suspension controller
Engine management units
Engine management systems

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DFMEA Example

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DFMEA Example (continued)

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DFMEA Example (continued)

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DFMEA Example (continued)

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Reference Documents
“Potential Failure Mode and Effect
Analysis – Reference Manual” by
Chrysler/Ford/GM 3rd edition