Design FMEA pg 1ConfidentialFAILURE MODE AND EFFECTS ANALYSIS - DESIGNSee last page for revision history:PROJECT NAME PROJECT NO.PART NO.ORIGINAL DFMEA DATE: DFMEA REV.DATE REVISED:

RELIABILITY ENGR.DESIGN/PRODUCT ENGR.APPROVEDMANUFACTURING ENGR.TEST ENGR.

COMPONENT or SUBASSEM.
A satisfied Microsoft Office user: When listing components, include details such as component part number, material, etc. which will be helpful to others reading or revising the DFMEA in the future.COMPONENT FUNCTION(S)
A satisfied Microsoft Office user: Function(s) is the task(s) which a component is expected to perform, either for the end customer or next operation as customer. It should be well defined using active verbs such as provide, contain, isolate, etc. that will allow better identification of potential failure modes. Describe a function in descriptive terms (ie carries 30 amps of current)FAILURE MODE(S)
A satisfied Microsoft Office user: Failure modes should be listed in physical terms, not as symptoms as described by the customer. Symptoms described by the customer are typically failure effects.) Failure modes can be thought of in terms of the reason that the component failed to perform its function. i.e. bulk resistance too high due, interface resistance too high) One should assume the component is manufactured as designedEFFECTS OF FAILURE
A satisfied Microsoft Office user: Effects are the symptoms observed by the customer such as loss of signal, overheating, burning, etc. Effects should be described in descriptive terms.SEV S
A satisfied Microsoft Office user: The severity of the effect is concerned only with the effect and not the failure mode. For example, an effect will have the same severity rating regardless of the associated failure modes.CLASS
US014632: Appropriate QS9000 symbol in accordance with customer requirement.CAUSE(S) OF FAILURE
A satisfied Microsoft Office user: A root cause is something the design engineer has direct control over. Again, assume the component will be mfg. as designed. Use brainstorming, cause and effect, etc. to identify causes.OCC O
A satisfied Microsoft Office user: The occurrence is the likelihood the failure mode will become active as a result of the failure cause. Do not rate the probability of the failure mode existing, but rather the probability the cause will lead to the mode becoming active.PREVENTION CONTROLS
A satisfied Microsoft Office user: Preventive Controls are those items or activities which will prevent or reduce the occurrence of failure cause or mode. Items in this column are controlled by the Design Engineer and are completed or already planned and will happen as a result of procedure or process. Preventative controls reduce the occurrence rating. DETECTION CONTROLS
A satisfied Microsoft Office user: Detection Controls are those verification or validation activities (controlled by the design, design procedure or design process) which will detect the failure cause or mode before the product is released for production. Items in this column are those that are completed or are already planned and will happen as a result of procedure or process.DET D
A satisfied Microsoft Office user: Detection rating is assessed as the ability of the current design control to determine if the potential failure cause (design weakness) will lead to the listed failure mode, or detect the occurrence of the listed failure mode before the design is released for production. Note: Detection controls reduce the detection rating. Preventative controls reduce the occurrence rating. If none of the current controls are detection controls (ie they are all preventative), then detection must be given a rating of 10) See AMP 402-29RPN OSDRECOMMENDED ACTION(S)
A satisfied Microsoft Office user: Those actions taken to reduce the occurrence or detection ratings, or eliminate the effect by eliminating the possibility of the failure mode. RESPONSIBILITY / TARGET DATEACTION(S) TAKENSEVOCC
A satisfied Microsoft Office user: The occurrence is the likelihood the failure mode will become active as a result of the failure cause. Do not rate the probability of the failure mode existing, but rather the probability the cause will lead to the mode becoming active. DET
A satisfied Microsoft Office user: The ability of the current design control to determine if the potential failure cause (design weakness) will lead to the listed failure mode or detect the occurrence of the listed failure mode before the design is released for production. Note: Detection controls reduce the detection rating. Preventative controls reduce the occurrence rating. If none of the current controls are detection controls (ie they are all preventative), then detection must be given a rating of 10) See AMP 402-29RPNRevison History:RevisionDateResponsible EngineerDescription

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GUIDELINESNote: This sheet is intended to serve as a guide for interpreting the columns within the FMEA form.

FAILURE MODE AND EFFECTS ANALYSIS - DESIGNSee last page for revision history:PROJECT NAME PROJECT NO.PART NO.ORIGINAL DFMEA DATE: DFMEA REV.DATE REVISED:

RELIABILITY ENGR.DESIGN/PRODUCT ENGR.ApprovedMANUFACTURING ENGR.TEST ENGR. COMPONENT
A satisfied Microsoft Office user: When listing components, include details such as component part number, material, etc. which will be helpful to others reading or revising the DFMEA in the future.COMPONENT FUNCTION(S)
A satisfied Microsoft Office user: Function(s) is the task(s) which a component is expected to perform, either for the end customer or next operation as customer. It should be well defined using active verbs such as provide, contain, isolate, etc. that will allow better identification of potential failure modes. Describe a function in terms of ways the function could fail (ie will not align to +/- .005)FAILURE MODE(S)
A satisfied Microsoft Office user: Failure modes should be listed in physical terms, not as symptoms as described by the customer. One should assume the component is manufactured as designed.EFFECTS OF FAILURE
A satisfied Microsoft Office user: Effects are the symptoms observed by the customer such as loss of signal, overheating, burning, etc. Effects should be described in descriptive terms.SEV S
A satisfied Microsoft Office user: The severity of the effect is concerned only with the effect and not the failure mode. For example, an effect will have the same severity rating regardless of the associated failure modes.CAUSE(S) OF FAILURE
A satisfied Microsoft Office user: A root cause is something the design engineer has direct control over. Again, assume the component will be mfg. as designed. Use brainstorming, cause and effect, etc. to identify causes.PREVENTION CONTROLS
A satisfied Microsoft Office user: Those items or activities which will prevent or reduce the occurrence of failure cause or mode. Items in this column are controlled by the Design Engineer and are completed or already planned and will happen as a result of procedure or process.OCC O
A satisfied Microsoft Office user: The occurrence is the likelihood the failure mode will become active as a result of the failure cause. Do not rate the probability of the failure mode existing, but rather the probability the cause will lead to the mode becoming active. DETECTION CONTROLS
A satisfied Microsoft Office user: Those items or activities controlled by the design, design procedure or design process which will detect the failure cause or mode. Items in this column are those that are completed or are already planned and will happen as a result of procedure or process.DET D
A satisfied Microsoft Office user: The ability of the current design control to determine if the potential failure cause (design weakness) will lead to the listed failure mode or detect the occurrence of the listed failure mode before the design is released for production. Note: Detection controls reduce the detection rating. Preventative controls reduce the occurrence rating. If none of the current controls are detection controls (ie they are all preventative), then detection must be given a rating of 10) See Tyco Electronics 402-29RPN OSDRECOMMENDED ACTION(S)
A satisfied Microsoft Office user: Those actions taken to reduce the occurrence or detection ratings, or eliminate the effect by eliminating the possibility of the failure mode. RESPONSIBILITY / TARGET DATEACTION(S) TAKENSEVOCC
A satisfied Microsoft Office user: The occurrence is the likelihood the failure mode will become active as a result of the failure cause. Do not rate the probability of the failure mode existing, but rather the probability the cause will lead to the mode becoming active. DET
A satisfied Microsoft Office user: The ability of the current design control to determine if the potential failure cause (design weakness) will lead to the listed failure mode or detect the occurrence of the listed failure mode before the design is released for production. Note: Detection controls reduce the detection rating. Preventative controls reduce the occurrence rating. If none of the current controls are detection controls (ie they are all preventative), then detection must be given a rating of 10) See Tyco Electronics 402-29RPN

When listing components, include details such as component part number, material, etc. which will be helpful to others reading or revising the DFMEA in the future.Function(s) is the task(s) which a component is expected to perform, either for the end customer or next operation as customer. It should be well defined using active verbs such as provide, contain, isolate, etc. that will allow better identification of potential failure modes. Describe a function in descriptive terms (ie carries 30 amps of current)Failure modes should be listed in physical terms, not as symptoms as described by the customer. Symptoms described by the customer are typically failure effects.) Failure modes can be thought of in terms of the reason that the component failed to perform its function. i.e. bulk resistance too high due, interface resistance too high) One should assume the component is manufactured as designedEffects are the symptoms observed by the customer such as loss of signal, overheating, burning, etc. Effects should be described in descriptive terms.The severity of the effect is concerned only with the effect and not the failure mode. For example, an effect will have the same severity rating regardless of the associated failure modes.A cause of failure is something the design engineer has direct control over. Again, assume the component will be mfg. as designed. Use brainstorming, cause and effect, etc. to identify causes.Preventive Controls are activities support design choices which prevent or reduce the occurrence of failure causes that lead to active failure modes. Items in this column are controlled by the Design Engineer and are completed or already planned and will happen as a result of procedure or process. Preventive controls reduce the occurrence rating. (i.e dimensional analysis to determine fits, clearances and interferences between components, Monte Carlo simulations, DOEs, ANSYS, etc.)The occurrence is the likelihood the failure mode will become active as a result of the failure cause. Do not rate the probability of the failure mode existing, but rather the probability the cause exists and will lead to the mode becoming active. Detection Controls are those verification or validation activities (controlled by the design, design procedure or design process) which will detect the failure cause or mode before the product is released for production. Items in this column are those that are completed or are already planned and will happen as a result of procedure or process.Detection rating is assessed as the ability of the current design control to determine if the potential failure cause (design weakness) will lead to the listed failure mode, or detect the occurrence of the listed failure mode before the design is released for production. Note: Detection controls reduce the detection rating. Preventative controls reduce the occurrence rating. If none of the current controls are detection controls (ie they are all preventative), then detection must be given a rating of 10) Recommended Actions are taken to reduce the occurrence or detection ratings, or eliminate the effect by eliminating the possibility of the failure mode.