If you are just entering the world of design, you will have to face a session of DFMEA some time or the other. DFMEA is an acronym for Design Failure Mode and Effects Analysis. In recent years, corporate settings are using DFMEA, a subset of FMEA or failure mode and effects analysis, as a valuable tool. It helps engineers spot potential risks in product design before they make any significant investments.

Engineers are using DFMEA as a systematic tool for mapping the early-warning system of a product. They use it to make sure the product functions not only as they intend it to, but also to keep users happy. It is like taking a peek into the future, catching any design flaws before they cause any major damage. Simply put, DFMEA helps to check the overall design of products and components, figuring out anything that might go wrong, and the way to fix it. This tool is specifically useful in industries involved with manufacturing, where it is important to prevent failure.

To use DFMEA effectively, the designer must look for potential design failures, observing them from all angles. Here is how they do it.

They first look for a failure mode, which essentially means how the design could possibly fail. For instance, your computer might freeze up when you open too many programs, which is one mode or type of failure.

Then they look for why the failure mode should happen. This could be due to a design defect, or a defect in the quality, system, or application of the part.

Next, the designers look for an effect of the failure. That is, what happens when there is a failure. In our example, a frozen computer can lead to a frustrated user.

In the last stage, designers look for the severity of the failure. They estimate how bad the failure could be for safety, quality, and productivity. Designers typically look for the worst-case scenarios.

To put it in a nutshell, DFMEA helps engineers figure out not only potential issues, but also the consequences of the failures. This way, they can prevent failures from happening in the first place.

However, DFMEA is never a one-man show. Rather, it is a team effort. Typically, the team has about 4 to 6 members—those who are fully knowledgeable about the product—and led by a product design engineer. The team members could include engineers with material background, and those from product quality, testing, and analysis. There may be people from other departments, like logistics, service, and production.

DFMEA is an essential tool in any design process. However, it is a crucial tool in industries handling new products and technology. This includes industries such as software, healthcare, manufacturing, industrial, defense, aerospace, and automotive. DFMEA helps them locate potential failure modes, reducing risks involved with introducing new technologies and products.

The entire DFMEA exercise is a step-by-step process and the team must think through each step thoroughly before they movie on to the next. It is essential they look for and identify the failure, and find out its consequences, before finding out ways to prevent it from happening.