The document outlines the Design Failure Mode and Effects Analysis (DFMEA) process, detailing steps such as reviewing design, identifying potential failure modes and their causes, ranking failures, and developing action plans to address them. Additionally, it emphasizes the importance of testing designs through various methods to ensure functionality and safety, highlighting the creation of test plans and the significance of prototyping. The document concludes with a focus on effective project delivery and the review process needed for successful implementation.

1. DFMEA :
Design for
Robustness
Pick one project from your
group for this section

2. DFMEA Steps
1. Review the design
2. Brainstorm potential failure modes
3. List potential effects of failure
4. List potential causes for each failure
5. Rank failures
a) Severity
b) Occurrence
c) Detection
d) RPN = Severity X Occurrence X Detection
6. Develop action plan
7. Implement fixes
8. Revisit potential failure risks

3. In a group, identify one project
to use as an example for this
exercise
Describe the project so the whole
group understands it

4. Brainstorm Failures
What could go wrong?
What could break?
Are there systems your design relies
upon?
o e.g. myEPICS authenticates through
Purdue’s career accounts
Are there things that could fail over
time?

5. Brainstorm a list of potential
failures and their causes for
one project

6. Rate failures
Rating
(1 to 10)
Severity How severe are the
consequences to
the failure
Occurrence How often are the
failures likely to
occur?
Detection How easily are the
failures detected?

7. DFMEA Calculations
Scores for Severity, Occurrence and
Detection
o 1 to 10
o 1 = Low
o 10 = High
Risk Priority Number (RPN)
o RPN =Severity X Occurrence X Detection

8. DFMEA Matrix
Failure mode Effect of
Failure
Cause of
failure Severity Occurrence Detection Rating

9. Take 5 potential failure
scenarios and rate them

10. Example
http://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis,
accessed 22 Aug. 2011

11. Example Chart

12. Identify the failure scenario that
should be addressed first

13. Develop an action plan to
address the failure scenario

14. Continue the process
Implement the plan to eliminate the
failure scenario
Revisit other potential failure risks
o Prioritize
o Eliminate failure scenarios
Continue until risks are below
determined thresholds
o Show to the design reviews for
confirmation

15. Can we get rid of all failures?
All cars have brakes that will eventually
fail
o Potentially catastrophic
o Early warning squealers to notify

16. Questions/Discussion

17. Testing in Design
William Oakes

18. Learning Objectives
 At the end of this session, you will be
able to:
1. Describe at least three ways to test your
projects
2. Describe how prototypes can be used in
testing
3. Categorize potential failures for a design

19. Testing
How do we know our projects will work?
o When we deliver it?
o For the intended life?
• What is the expected life?
How do we know the project will
function like we want and for the users
intended?
How do we know we are meeting the
right needs?

20. Testing
Designers have to know that their
design will function
o Plan testing along the way
Tests look at
o Function – does it perform like we intended
• Under what conditions?
o User testing – does it meet needs
• Can people use it as intended

21. GE Jet Engines
Test examples:
o Performance – did it produce enough thrust
to fly the plane?
o Endurance – Will it last?
o Safety – is it safe?

22. Jet Engine Testing
Proof of concept
o Analysis – computer tests
o Component tests
Fit and form
o CAD models
o Wooden and/or rapid prototype models
• Can we reach things?
o Interface fits

23. Jet Engine Testing
Assembly tests
Ground tests
o Performance
o Endurance – simulate flights
o Safety – what could go wrong
• Bird strikes
• Water (rain) ingestion
• Hail ingestion
• Blade failures
Flight tests

24. Other experiences
Test in the proper conditions
o Refrigerators testing in an open
room rather than against a wall
Medical equipment
o Tested on range of people
Food products
o Taste, preferences and buying habits

25. “Fail quickly and cheaply”
Prototyping….rough, quick, very
interative
o IDEO working with Gyrus ACMI to
design new apparatus for
operating on delicate nasal tissues
o Prototype:
http://cataligninnovation.blogspot.com/2008/11/prototyping-foundational-competency-of.html

26. Think, pair, share….
What questions and/or issues need to
be tested for your current project?
Find one or two others to share your
answers
o Introduce yourself
o Describe your project
o Answer the first question

27. More discussion
Individually
o What tests need to be done on the project?
Share what you answered for your
project with the same person or pair.

28. Test plans
At GE and other companies there are
teams that are dedicated on testing
o How do we take an engine and test it?
o How do we test a new medical device?
o How to we insure that the software works?
Create a test plan for your design
o What tests need to be done?
o What will they measure?
o What are the criteria for success and failure?

29. Test Plans
What will be
tested
Who and/or
where will it
be done
What will be
measured?
Success or
failure
Test #1
Test #2
Test #3
Test #4
Clearly define what will
be done and by whom

30. Sample Test Plan Template
Test Plan Template.docx on Canvas
 1 Description of Product
 1.1 Components of interest
 1.1.1 Dimensions
 1.1.2 Photographs
 1.2 Specific, important characteristics
 1.2.1 Materials, tolerances, limitations
 1.2.2 How close is this test vehicle to the expected final product
 2 Objectives of Test
 2.1 Overall goal (characterization, optimization, test to failure, e.g.)
 2.2 Specific parameters to be measured
 2.3 Target values of outputs
 2.4 Test Success Criteria Definition
 2.4.1 What new knowledge will you have gained
 2.4.2 How will you use the new knowledge
 2.4.3 Is the comfort/safety of humans interacting with the product compromised
 2.5 Is a redesign required

31. Discussion
In your pairs or groups, identify one test
that was proposed and develop the
who, what, where, why and the success
criteria

32. Test tips
User testing and prototypes
Component tests
o Small parts that are demonstrated can help
hold the team accountable
Fit and form tests
Simulate usage
o Walked on the Martian surface
Use Cases – software
o Build a case or example of how to use the
design and see if it works correctly

33. Another example…
Testing in the proper conditions

34. Delivery of
Projects

35. Delivery Steps
Review the delivery checklist used at
Purdue
Modify the checklist assuming that your
students will finish their designs and deliver
them to a user or client

36. Questions/Discussion