Welcome — Day 1

2012
Failure Mode and Effects Analysis

2012 Ford Motor Company - CQDC Training - August 2012 1

 Course Purpose
Participants will be able to function as effective
FMEA team members by being able to:

Define what an FMEA is, list the benefits and
distinguish between three types of FMEAs

Describe how to use the FMEA Working Model in order
to complete Design and Process FMEAs

Learn new robustness methodologies

Explain how FMEAs fit into Ford’s quality strategies,
GPDS timings and Ford Production System (FPS)
strategies

Demonstrate proficiency in using the FMEA Handbook
2012 Ford Motor Company - CQDC Training - August 2012 2
 Participant Materials
FMEA Handbook
Version 4.2
Page
Number

Participant Guide
2012 Ford Motor Company - CQDC Training - August 2012 3
 FMEA -- An Introduction

Why Do FMEAs?

Definition, Purpose,
Benefits, Types

FMEA Working Model
Introduction
Generating / Managing

Team Approach

2012 Ford Motor Company - CQDC Training - August 2012 4

 FMEA -- Definition
Structured group of activities which ...

Identify potential failure modes

Identify and prioritize actions

Document the process

2-3 2012 Ford Motor Company - CQDC Training - August 2012 5

 FMEA Purposes
Timing & Quality
of Potential Failures
Failures

FMEA

JOB 1 Time
2-5 2012 Ford Motor Company - CQDC Training - August 2012 6
 FMEA Purposes
Customer Orientation

Unreliable Excellent
VDS/ SDS

Products Products

Reliable
Disaster Products
Customer
Doesn't Want
Design and Process Orientation
FMEA

2-5 2012 Ford Motor Company - CQDC Training - August 2012 7

 FMEA -- Types
System
Design/ Design
Process FMEA Sub-System
Concept
FMEA Component

System
Process Assembly Sub-System
Component
FMEA System
Manufacturing Sub-System
Component

Machinery
FMEA

2-7 2012 Ford Motor Company - CQDC Training - August 2012 8

 Change Point Approach
FMEAs are living documents,
and are updated when ...

New design or process is planned

Modification to a component,
process or system is planned,
including those due to Global 8D

Component is to be used in new
environment, location, or application

2-112012 Ford Motor Company - CQDC Training - August 2012 9

 Benefits/Uses--Concept FMEAs
Design

Helps select optimum concept
Concept
Process
Helps set targets for the concept

Helps Identifies testing

requirements

Helps determine if hardware

system redundancy is required

2-122012 Ford Motor Company - CQDC Training - August 2012 10

 Benefits/Uses--Design FMEAs

Aids in evaluating requirements
and alternatives
Design

Aids in initial design for DFM,
Concept DFA, DFS, and DFR
Process
Helps plan thorough and efficient
development and validation
programs

Develops a prioritized list for
actions

Helps identify potential special
characteristics

Helps validate DVPs and SDSs
2-132012 Ford Motor Company - CQDC Training - August 2012 11
 Benefits/Uses--Process FMEAs
Design
Assesses Effects on all customers
Concept
Identifies potential Manufacturing
Process and Assembly causes to focus
controls on reducing occurrence
and/or increasing detection

Develops a prioritized list for actions

Documents the results of the
manufacturing or assembly process

Identifies confirmed special
characteristics requiring special
controls
2-152012 Ford Motor Company - CQDC Training - August 2012 12
 FMEA Working Model
What What can be done?
How bad
are the
is it? • Design Changes
Effect(s)?
• Process Changes
What are the Step 1
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Step 2 What How often
Procedures, or
are the does it
Guides
Cause(s)? happen?

What can go wrong?

• No Function
How can
• Partial/Over Step 3 this be
Function/Degraded prevented
Over Time and
detected?
• Intermittent
Function How good
is this
method at
• Unintended detecting
Function it?

3-202012 Ford Motor Company - CQDC Training - August 2012 13

 FMEA Form
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C Potential O D Action Results

Potential Potential l c Current Controls e Responsibility
Failure S a Cause(s)/ c t R. Recommended & Target
Effect(s) of Mechanism(s) Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
Function of Failure r Prevention Taken
v s c N. v c t N.

What What can be done?

How bad
are the
is it? • Design Changes
Effect(s)?
• Process Changes
What are the Step 1
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Step 2 What How often
Procedures, or
are the does it
Guides
Cause(s)? happen?

What can go wrong?

• No Function
How can
• Partial/Over Step 3 this be
Function/Degraded prevented
Over Time and
detected?
• Intermittent
Function How good
is this
method at
• Unintended detecting
Function it?

3-202012 Ford Motor Company - CQDC Training - August 2012 14

 Generating FMEAs
Who initiates? Who prepares? Who updates?

When to Failure When started

discard? and updated?
Mode
FMEAsand
How is FMEA Effects Relationship
documented? Analysis to GPDS?

When is FMEA Who is FMEA

complete? customer?

2-172012 Ford Motor Company - CQDC Training - August 2012 15

 FMEAs and Systems Engineering
GPDS Timing and Process Flow
UN Timing UNV0 UNV1 UNV2 M1DJ
UP Timing UPV0 UPV1 UPV2 FDJ

DFMEA
Pre- Failure Prevention Detection Recommended Ongoing updates as required
Functions Causes
Work Modes Controls Controls Actions

Manufacturing Input
YC/YS CC/SC
Initial Definition Iterate and update as required Agreement
FAF03-111-y FAF03-111-y
System Level

Ongoing updates as
PFMEA required

DFMEA

Prevention

Detection
Controls
Controls

mended
Ongoing updates as required

Causes

Recom

Actions
Pre- Modes
Failure

Functions
Work

YC/YS Iterate and CC/SC

Initial Definition update as Agreement
FAF03-111-y required FAF03-111-y

Component Level
Ongoing updates as
PFMEA required

2-22
2012 Ford Motor Company - CQDC Training - August 2012 16
 Section Summary

Why Do FMEAs?

Definition, Purpose,
Benefits, Types

FMEA Working Model
Introduction

Generating / Managing

Team Approach

2012 Ford Motor Company - CQDC Training - August 2012 17

Design FMEA -- An Introduction

Identify DFMEA Team

Establish Scope

Describe Function
Design FMEA » Brainstorming
Introduction » Function Trees

Practice Exercise 1

2012 Ford Motor Company - CQDC Training - August 2012 18

 Design FMEA
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C O D Action Results

Potential Potential c Current Controls Responsibility
Potential l Cause(s)/ e
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
of Failure Prevention Taken
Function v s r c N. v c t N.

What What can be done?

How bad
are the
is it? • Design Changes
Effect(s)?
• Process Changes
What are the Step 1
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Step 2 What How often
Procedures, or
are the does it
Guides
Cause(s)? happen?

What can go wrong?

• No Function
How can
• Partial/Over Step 3 this be
Function/Degraded prevented
Over Time and
detected?
• Intermittent
Function How good
is this
method at
• Unintended detecting
Function it?

2012 Ford Motor Company - CQDC Training - August 2012 19

 Design FMEA -- Team
Facilitator
Representatives
Support from:
Team • Customer
Service
Design Engineer • Suppliers
CORE
Manufacturing / • Vehicle
Team Evaluation
Process Engineer
Verification
• Corporate
Quality

3-6 2012 Ford Motor Company - CQDC Training - August 2012 20

 Design FMEA -- Scope

Is the boundary or extent of the analysis

Defines what is included and excluded

Scope incorrectly done:
» Lengthens analysis
» Misses target analysis
» Identifies wrong team membership

3-7 2012 Ford Motor Company - CQDC Training - August 2012 21

 Design FMEA -- Scope
Once core team is established...

Create a boundary diagram

Identify the boundary for analysis

Confirm composition of support
team

3-8 2012 Ford Motor Company - CQDC Training - August 2012 22

 Constructing Boundary Diagrams
Exhaust Sensors Acoustical
(HEGO/CMS) NVH Pads

Engine Emission
Exhaust Coated Internal cones Control Subsystem
Manifold Substrate & Insulation
Acoustical Control
Components Subsystem
Engine System Catalytic
Converter Shields and
Assembly Attachments Subsystem
Body/Floor Pan
Frame and Mounting
Shell/Cone Mounts System
Vehicle fluid Seals Exhaust Pipes and
•A/C condensate
Support System
•Engine coolant
•Transmission coolant
•Oil from oil pan Environment:
Human
• Ambient temperature
• Humidity
• Road load (vibration)
• Off Road (debris/rock)
• Road Salt/ mud/ water

3-9 2012 Ford Motor Company - CQDC Training - August 2012 23

Boundary Diagram -- Example
Headlamp Assembly

2012 Ford Motor Company - CQDC Training - August 2012 24

Boundary Diagram -- Example
Vertical Trimmer Assembly

2012 Ford Motor Company - CQDC Training - August 2012 25

 Boundary Diagram -- Example
Assembly Service

Hood Adjuster User

(Clearance) Socket

Lateral
Location Clips
Vehicle Body Screw 2
Upper Cross Reflector
Vibration
Member

2012 Ford Motor Company - CQDC Training - August 2012 26

 Practice Exercise 1-a
Boundary diagram

2012 Ford Motor Company - CQDC Training - August 2012 27

 Presentation -- Practice 1-a

Technical Team
Debrief Debrief

2012 Ford Motor Company - CQDC Training - August 2012 28

 Interface Matrix

Recommended robustness tool that
acts as an input to a Design FMEA

Identifies and quantifies the strength
of system interactions by:
» Showing whether the relationship is
necessary or adverse
» Identifying the type of relationship

3-102012 Ford Motor Company - CQDC Training - August 2012 29

 Example Interface Matrix

Mounts - Catalytic Converter

Internal Cones & Insulation -

Coated Substrate - Catalytic
Seals - Catalytic Converter

Engine Emission Control

Shell/Cone - Catalytic

Acoustical NVH Pads

Catalytic Converter

Exhaust Manifold
Environment

Subsystem
Converter

Converter
Shell/Cone - Catalytic 2 -1 -1 2 -1 2 -2 -2
Converter
2 2 -1 2 -1 2 -1 -1 -1 -1
Seals - Catalytic Converter
Coated Substrate - Catalytic 2 -1 2 -1 -1 2 2 2
Converter
-1 -1 2 -1 2 -1 -1 -2 -2
Mounts - Catalytic Converter

Internal Cones & Insulation - 2 2 -1 -1 -1

Catalytic Converter
-1 -1 -1 -1 -1
Environment

2 -1 2
Exhaust Manifold

Engine Emission Control 2 2

Subsystem
-2 -2 -1 -1 -2 -2 -1 -1
Acoustical NVH Pads

3-112012 Ford Motor Company - CQDC Training - August 2012 30

 Interface Matrix Legend
P E P: Physically touching E: Energy transfer

I M I: Information exchange M: Material exchange

Numbers in each corner represent the above

interface types, with values denoting the following:
+2 Interaction is necessary for f unction
+1 Interaction is beneficial, but not absolutely necessary
for functionality
0 Interaction does not affect functionality
-1 Interaction causes negative effects but does not
prevent functionality
-2 Interaction must be prevented to achieve
functionality

3-112012 Ford Motor Company - CQDC Training - August 2012 31

 P-Diagram

Recommended structured tool to identify
intended inputs and outputs for a
function

Describes noise factors, control factors,
ideal function, and error states

Assists in the identification of:
» Potential Causes for failure
» Failure Modes
» Potential Effects of failure
» Current Controls
» Recommended Actions
3-142012 Ford Motor Company - CQDC Training - August 2012 32
 Example P-Diagram
Piece to Piece Variation Customer Usage External Environment
- Material
Materi al - Short, low speed trips - Ambient temperature
- Assembly process - High speed/trailer tow - Road load (vibration)
- welding process - Fuel type & quality/sulfur level Off Road (debris/rock)
- Canning forces: Clamping force/wrap - Service damage/ shipping mishmishandling
andling - Road Salt/ mud/ water
tightness/crimping force - Driving with engine errors
- Substrate Wash coat Coating System Interactions
composition Changes Over Time/Mileage Heat Shield/NVH Pads Pressure
- misbuild/ mislabels - Blockage/restriction Exhaus t Manifold
Exhaust Manifold (Welded)
(Welded) Leaks
Leaks
- Orientation and centrality - Weld deterioration/
deterioration/ fatigue
fatigue Engine misfire Heat
- Mount gap (Mat/Wire) / Shell OD - Substrate retention (Mount degradation) Oil contamination
- Dimension (Assembly) - Substrate erosion/breakage Power train load (vibration)
- Catalyst chemical ageing Dynamic load (engine induced)
- corrosion of shell Calibration
- Loosening of heat shield Backpressure

Noise Factors
INPUT SIGNAL
SIGNAL: OUTPUT RESPONSE
Mass
RESPONSE
- Exhaust Gas Composition Catalytic
Catalyti Y1 = Regulated Emission ( HC, CO, NOx)
Energy Converter
- Thermal
cConvert [grs /mile]
- Mechanical
Assembl
Assembly
er Y2 = Non -Regulated Emission (H 2S)
- Chemical y [ppm/test]
- Pressure

Control Factors
Mechanical Error States
States: :
- Noise/Rattle
- Shell Design & Material
- Power Loss
- Mount Material (Mat/Wire)/Seals
- Substrate Geometry (contour & length) - Heat (internal & external heat mgt)
m gt)
- Exhaust leak
- Substrate Cell Density & wall thickness
- Check Engine MIL
- Packaging
Packagin gLocation
Location &&Volume
Volume
- Flow Distribution (Pipe/Cone Geometry) - Odor/Smell
- Output gases do not meet emission
Chemical requirements
- Wash
W ash coat Technology
- Selection of Precious Metal Loading/Ratio

3-162012 Ford Motor Company - CQDC Training - August 2012 33

 Practice Exercise 1-b
P-diagram

2012 Ford Motor Company - CQDC Training - August 2012 34

 Robustness Checklist

Summarizes key robustness Attributes

and Design Controls.

Links the DFMEA and the 5 noise
factors to the Design Verification Plan
(DVP); i.e., the Robustness Checklist is
an input into the DVP.

Should be a key document to review as
part of the design review process.
3-612012 Ford Motor Company - CQDC Training - August 2012 35
 Robustness Checklist

3-622012 Ford Motor Company - CQDC Training - August 2012 36

 Robustness Checklist

3-622012 Ford Motor Company - CQDC Training - August 2012 37

 Best Practice FMEA

2-6 2012 Ford Motor Company - CQDC Training - August 2012 38

FMEA (with Robustness Linkages) Process
Qualifies and clarifies the relationships
Boundary
between Systems
Diagram

Identifies and quantifies the strength

Interface
of System Interactions
Matrix

Identifies Noise and Control

P-Diagram Factors and Error States

FMEA (with
Robustness
Linkages)

Summarizes Error States, Noise Factors,

Robustness
and associated Design Controls
Checklist

Design Verification
Plan (DVP)

2012 Ford Motor Company - CQDC Training - August 2012 39

 FMEA Flow
Failure Mode
Failure Mode Avoidance
Avoidance Quality History

Boundary
Boundary
Diagram
Diagram

Interface
Interface
Matrix
Matrix

Mistakes
Mistakes Robustness
Robustness Problem
Problem

REDPEPR
FMEA
FMEA P-Diagram
With Campaign
With Campaign & &
Quality History
Quality History RRCL
RDM

DesignVerification
Design Verification
Plan (DVP)
Plan (DVP)

2-8 2012 Ford Motor Company - CQDC Training - August 2012 40

 Header Information

Complete each field

Enter names of all team members

Enter team leader name as
‘prepared by’

3-172012 Ford Motor Company - CQDC Training - August 2012 41

 Determine Function
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C Potential O D Action Results

Potential Potential l c Current Controls e Responsibility
Cause(s)/
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
Function of Failure r Prevention Taken
v s c N. v c t N.

What What can be done?

How bad
are the
is it? • Design Changes
Effect(s)?
• Process Changes
What are the Step 1
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Step 2 What How often
Procedures, or
are the does it
Guides
Cause(s)? happen?

What can go wrong?

• No Function
How can
• Partial/Over Step 3 this be
Function/Degraded prevented
Over Time and
detected?
• Intermittent
Function How good
is this
method at
• Unintended detecting
Function it?

3-212012 Ford Motor Company - CQDC Training - August 2012 42

 What is Function?

Design intent or engineering
requirement

Written in verb-noun measurable
format

Representation of all wants, needs
and requirements, both spoken and
unspoken for all customers and
systems
3-222012 Ford Motor Company - CQDC Training - August 2012 43
 Item Function Worksheet
ITEM FUNCTION
DESCRIPTION
FUNCTION:
What is the item supposed to do?
What is the item not supposed to do?
List all the functions and separate them from the specifications.

List All Functions Specifications

Function Description: How Much?

Verb - Noun When?

3-242012 Ford Motor Company - CQDC Training - August 2012 44

 Function Trees

Provide an organized approach to
identify the essential features of a
product (or process sometimes)

Help ensure that ‘unspoken’ and
‘spoken’ requirements are defined

Provide a graphical representation
of functions to ensure clear, total
team understanding

B-182012 Ford Motor Company - CQDC Training - August 2012 45

 Constructing Function Trees
HOW ? WHY ?
Second
Level
First Third
Level Level

B-192012 Ford Motor Company - CQDC Training - August 2012 46

 Guidelines

Brainstorm all functions (VERB - NOUN)

Document individual functions by
asking “HOW is function achieved?”

Repeat left to right, until actionable level

Use worksheet to check that actionable
level is measurable

Work right to left and check structure by
asking “WHY is function included?”
B-202012 Ford Motor Company - CQDC Training - August 2012 47
 Section Summary

Identify DFMEA Team

Establish Scope, Boundary
Diagram

P-Diagram, Interface Matrix

Design FMEA
Describe Function

Introduction » Function Trees

2012 Ford Motor Company - CQDC Training - August 2012 48

 Design FMEA Path/Step 1

Failure Modes

Effects -- Severity

Potential Special
Characteristics
DFMEA - Path 1

Recommended Actions

2012 Ford Motor Company - CQDC Training - August 2012 49

 Design FMEA – Path/Step 1
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C O D Action Results

Potential Potential c Current Controls Responsibility
Potential l Cause(s)/ e
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
of Failure Prevention Taken
Function v s r c N. v c t N.

What What can be done?

How bad
are the • Design Changes
is it?
Effect(s)?
• Process Changes
What are the Step 1
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Procedures, or
Guides

What can go wrong?

• No Function

• Partial/Over
Function/Degraded
Over Time

• Intermittent
Function

• Unintended
Function

3-212012 Ford Motor Company - CQDC Training - August 2012 50

 Potential Failure Modes
P O T E N T IA L
F A IL U R E M O D E A N D E F F E C T S A N A L Y S IS

Ite m C O C u rr e n t D A c tio n R e s u lts

l P o te n tia l c D e s ig n e
P o te n tia l P o te n tia l C a u s e (s )/ R ec om m en de d R e s p o n s ib ility
F a ilu r e E ffe c t(s ) o f S a c C o n tr o ls t R. & T arg et A c tio n s S O D R.
e s M e c h a n is m (s ) u – P re v e n tio n e P. A c tio n (s ) e c e P.
M o de F a ilu r e o f F a ilu r e C o m p le tio n D a te Taken
F u n c tio n v s r – D e te c tio n c N. v c t N.

Function
1

Function
2

Function
3
Potential Failure Modes:
• No function
Function
4
• Partial/Over Function/Degraded
Function
Over Time
n
• Intermittent function
• Unintended function

3-252012 Ford Motor Company - CQDC Training - August 2012 51

 Failure Modes -- Vertical Trimmer
Function: Adjust Light Beam X° in Both Directions

Failure Mode Type Potential Failure Mode

No function No adjustment
Partial/Over Function/
Degraded Over Time Adjustment in one direction
Intermittent function Adjustment sometimes and
not at others (not in cold)
Unintended function None known

3-252012 Ford Motor Company - CQDC Training - August 2012 52

 Effects of Failure Modes
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C O D Action Results

Potential l Potential c Current Controls e Responsibility
Potential Cause(s)/
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
of Failure Prevention Taken
Function v s r c N. v c t N.

What What can be done?

How bad
are the • Design Changes
is it?
Effect(s)?
• Process Changes
What are the
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Procedures, or
Guides

What can go wrong?

• No Function

• Partial/Over
Function/Degraded
Over Time

• Intermittent
Function

• Unintended
Function

3-302012 Ford Motor Company - CQDC Training - August 2012 53

 Effects of Failure Modes
P O T E N T IA L
F A IL U R E M O D E A N D E F F E C T S A N A L Y S IS

Ite m C O C u rr e n t D A c tio n R e s u lts

l P o te n tia l c D e s ig n e
P o te n tia l P o te n tia l C a u s e (s )/ R ec om m en de d R e s p o n s ib ility
F a ilu r e E ffe c t(s ) o f S a c C o n tr o ls t R. & T arg et A c tio n s S O D R.
e s M e c h a n is m (s ) u – P re v e n tio n e P. A c tio n (s ) e c e P.
M o de F a ilu r e o f F a ilu r e C o m p le tio n D a te Taken
F u n c tio n v s r – D e te c tio n c N. v c t N.

Potential Effects of Failure Modes:

• Part / Sub-component
• Next Higher Assembly
• System
• Vehicle
• Government Regulations
• Customer (Internal and End User)

3-312012 Ford Motor Company - CQDC Training - August 2012 54

 Design Effects List

B-222012 Ford Motor Company - CQDC Training - August 2012 55

 Design FMEA -- Severity
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C O D Action Results

Potential Potential c Current Controls Responsibility
Potential l Cause(s)/ e
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
of Failure Prevention Taken
Function v s r c N. v c t N.

What What can be done?

How bad
are the • Design Changes
is it?
Effect(s)?
• Process Changes
What are the
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Procedures, or
Guides

What can go wrong?

• No Function

• Partial/Over
Function/Degraded
Over Time

• Intermittent
Function

• Unintended
Function

3-322012 Ford Motor Company - CQDC Training - August 2012 56

 Suggested Severity Evaluation
Criteria
Effect Criteria: Severity of Effect Ranking
Failure to Meet Safety Potential failure mode affects safe vehicle operation and/or involves 10
noncompliance with government regulation without warning.
and/or
Regulatory Potential failure mode affects safe vehicle operation and/or involves 9
noncompliance with government regulation with warning.
Requirements
Loss of primary function (vehicle inoperable, does not affect safe 8
Loss or Degration of vehicle operation).
Primary Function Degradation of primary function (vehicle operable, but at reduced 7
level of performance).
Loss of secondary function (vehicle operable, but comfort 6
Loss or Degration of /convenience functions inoperable).
Secondary Function Degradation of secondary function (vehicle operable, but comfort 5
/convenience functions at reduced level of performance).
Appearance or Audible Noise, vehicle operable, item does not 4
conform and noticed by most customers (> 75%).
Appearance or Audible Noise, vehicle operable, item does not 3
Annoyance conform and noticed by many customers (50%).
Appearance or Audible Noise, vehicle operable, item does not 2
conform and noticed by discriminating customers (< 25%).
No Effect No discernible effect. 1
2012 Ford Motor Company - CQDC Training - August 2012 57
 DFMEA Severity Rating Example
Item Potential S
Potential
Failure Effects of Failure E
Function Mode V
Part: May be stripped during
Does not
Vertical
maintain
adjustment (7) 10
Trimmer/ Next Higher Assembly: Headlamp
adjustment cannot be adjusted (6)
Retains System: Misaligned lightbeam (8)
Setting Vehicle: Impaired night/fog
performance (7)
Govt Regs: Non-compliance (10)
Customer: Impaired night/ fog (7)

2012 Ford Motor Company - CQDC Training - August 2012 58

 Identify Potential Special Characteristics

Design FMEA

S=9
S=10

YC

3-342012 Ford Motor Company - CQDC Training - August 2012 59

 DFMEA -- Recommended Actions
POTENTIAL
FAILURE MODE AND EFFECTS ANALYSIS

Item C O D Action Results

Potential Potential c Current Controls Responsibility
Potential l Cause(s)/ e
Failure Effect(s) of S a Mechanism(s)
c t R. Recommended & Target Actions S O D R.
Mode Failure e s u Detection e P. Action(s) Completion Date e c e P.
of Failure Prevention Taken
Function v s r c N. v c t N.

What What can be done?

How bad
are the • Design Changes
is it?
Effect(s)?
• Process Changes
What are the
Functions,
• Special Controls
Features or
Requirements?
• Changes to
Standards,
Procedures, or
Guides

What can go wrong?

• No Function

• Partial/Over
Function/Degraded
Over Time

• Intermittent
Function

• Unintended
Function

3-352012 Ford Motor Company - CQDC Training - August 2012 60

 Practice Exercise 2

Failure Modes
Effects
Severity
Recommended
Actions
Classifications

2012 Ford Motor Company - CQDC Training - August 2012 61

 Presentation -- Practice 2

Technical Team
Debrief Debrief

2012 Ford Motor Company - CQDC Training - August 2012 62

 Section Summary

Failure Modes

Effects -- Severity

Potential Special
Characteristics
DFMEA - Path 1

Recommended Actions

2012 Ford Motor Company - CQDC Training - August 2012 63