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Multipoint DFMEA for Mechatronic and Electronic Systems

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Seminar Content

This two-day, hands-on seminar is intended to offer insight into, and hands-on experience with, the linkages between various aspects of the Advanced Product Quality Planning (APQP) process. Specifically, the development and linkage of Block Diagrams, Interface Matrix, System and Design FMEAs and Design Verification (Test) Plans (DVPs) are addressed.

A key aspect of this class is to explain how single and multipoint faults can be incorporated into the same FMEA and how it can be used to easily build linked FTAs and FMEDAs. This follows a key breakthrough methodology that Omnex has developed for FMEAs.

SFMEAs are performed during the Design phase of APQP for Risk Management and Prevention. SFMEAs are used to identify Special Requirements, Critical Items and Key Characteristics to assist in the flow-down to sub-assemblies and components.

This seminar includes breakout exercise sessions using an example of appropriate complexity so that the participant has the opportunity to grasp both System FMEA and Design FMEA concepts. The key part of the course is applying the concepts during the breakout sessions which is explained using a battery pack case study.

Who Should Attend

This seminar is designed for those involved in the design, development, and production of electrical and electronic based vehicle products, including the systems and hardware engineers, and managers.  Basically, all those responsible for the development and implementation of hardware and systems in motor vehicles. Omnex has a Software FMEA course for software engineering.

Commontitles of attendees include E/E & H/W Project Managers, HW Developers, Hardware Design Engineers, Systems Engineers and Functional Safety Engineers, or similar titles.

Recommended Training and/or Experience

Participants should possess a working knowledge of quality systems and methodologies.

Seminar Materials

Each participant will receive extensive course material.

Seminar Goals

  • Explain the difference between DFMEA and SFMEA

Demonstrate an ability to properly construct a Boundary (Block) Diagram

  • Explain how to incorporate single and multipoint FMEAs into the same FMEA (Omnex method)
  • How to build a FMEA that links with FTA and FMEDA (Omnex method)
  • Explain the use of an inter-relationship matrix to identify relationships between components and higher level systems
  • Demonstrate an ability to properly and effectively complete all items in the DFMEA process

Identify Functions, Requirements, Failure Modes, Causes and Controls and properly enter the information in a DFMEA

  • Demonstrate how to use the output from a DFMEA to develop a test plan (DVP&R)
  • Explain how a DFMEA can help identify effects and severity for a process failure mode
  • Identify special characteristics in product design
  • Continual improvements with a focus on the use of Sev, Sev x Occ, and Sev x Occ x Det ratings

Seminar Agenda

  • Setting the Stage: APQP Overview
  • Introduction to Failure Mode and Effects Analysis (FMEA)
  • Developing an FMEA
  • Design FMEA Prerequisites
    • Breakout Exercise: Function Worksheet
    • Breakout Exercise: Boundary Diagram
  • Developing the Design FMEA
    • Breakout Exercise:Item / Function and Requirements
    • Breakout Exercise: Potential Design Failure Modes
    • Breakout Exercise: Potential Causes
    • Breakout Exercise: Design Controls
    • Breakout Exercise: Effects and Severity
    • Breakout Exercise: Review Identified Special Charatceristics
    • Breakout Exercise: Risk Analysis and Mitigation
    • Breakout Exercise: Implementation
    • Breakout Exercise: Thinking Ahead to FTA and FMEDA (instructor-led)
  • Test Planning and Reporting
    • Breakout Exercise: DVBP&R
  • Summary

Multipoint DFMEA for Mechatronic and Electronic Systems

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