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Understanding Core Tools: Design Failure Modes and Effects Analysis (DFMEA) and Design Validation Plan & Report (DVP&R)

Seminar Content

This one-day overview addresses the use of Design Failure Mode and Effects Analysis and Design Verification Planning in new product to ensure a successful launch of new products/processes and capable serial production.

The approaches discussed and employed in this course are consistent with the intent and guidelines in the APQP 2nd Edition, FMEA 4th Edition, and PPAP 4th Edition manuals issued by GM, Ford and FCA through the AIAG.

Who Should Attend

  • Program Managers
  • Product Mangers
  • Quality Managers
  • Design Engineers
  • APQP Team Members

Recommended Training and/or Experience

Participants should possess a basic understanding of your organization and its processes.

Seminar Materials

Each participant will receive a seminar manual and a workbook including all team breakout exercises.

Seminar Goals

Understand how to develop and use DFMEA and DVP&R to identify and address design risk during the product development process and in support of the manufacturing process development process

Seminar Outline

  • APQP Phases: Key Phase Deliverables (Outputs)
  • DFMEA Introduction
    • DFMEA Purpose
    • DFMEA Objectives
    • New Products
    • Linkages
  • DFMEA Preparation
    • Define the Customer
    • Identify Specific Functions and Requirements
    • Robust Designs
    • Breakout Exercise 1: Boundary (Block) Diagram
    • Breakout Exercise 2: Parameter (P) Diagram
    • Other Inputs to DFMEA
  • Developing the DFMEA
    • Starting the DFMEA Form
    • Design Failure Modes
    • Potential Design Causes
    • Potential Controls & Prevention
    • Potential Effect & Severity
    • Action Planning
    • Evaluating and Maintaining DFMEAs
    • Breakout Exercises 3-8: Developing the DFMEA
  • Design Verification Plan & Report (DVP&R)
    • Objectives of DVP&R
    • DVP Format & Flow
    • Management Responsibility for DVP
    • Challenges to Development


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