Design Failure Mode Effect and Analysis (DFMEA)

Course Summary

Design Failure Mode Effect and Analysis (DFMEA) is a very important tool for the design engineer to develop designs which are reliable and safe.

This course will take you through the concepts and process of developing a DFMEA.

What the course will cover?
- Need for DFMEA
- Defining failure modes
- Cause and Root cause analysis using Fishbone diagrams
- Evaluation of Risk - Severity, Occurence and Detection
- What is Design prevention control and Design detection control / Design verification
- Grading of severity, occurence and detection
- The systematic process of DFMEA
- What is B diagram and how to prepare B diagram with multiple examples
- What is P diagram and how to prepare P diagram with multiple examples
- DFMEA walkthrough of a Bicycle
- Exercises for learning by doing.

The course is well suited for Mechanical design engineers or aspiring students who want to learn how to design effectively and consider possible failure modes.
The class focusses on the concepts and underlying reasoning rather than a descriptive approach .

Developing a good DFMEA is critical for complex system engineering work and hence its a key skill to develop for career growth and innovation.

Course Curriculum

Introduction
4 Lessons
- Introduction
  Start
- Risks associated in Mechanical design and need for DFMEA
  Preview
- What DFMEA accomplishes
  Start
- 7 step process of DFMEA as per AIAG & VDA Standard
  Start
Structure Analysis - Boundary Diagram
5 Lessons
- Structure analysis
  Start
- B diagram and Example of Bike
  Start
- B diagram Wrench
  Start
- B diagram Scissor jack
  Start
- External B diagram Seat Belt system
  Start
Function Analysis - P diagram
10 Lessons
- Function Analysis
  Start
- Terms in Function Analysis
  Start
- Functions , Functional requirements and Non Functional Requirements
  Start
- P Diagram - Introduction
  Start
- Function Tree - Windshield Wiper System
  Start
- Function Tree and Functional decomposition of a Bicycle
  Start
- Parameter Diagram Framework as per AIAG and VDA standard
  Start
- P Diagram of an Adjustable Wrench
  Start
- P diagram of a Car Scissor Jack
  Start
- P Diagram of Bicycle
  Start
Basics of DFMEA
15 Lessons
- Failure Analysis
  Start
- Defining Failure modes
  Start
- Mechanical Phenomena of failure modes
  Start
- Cause , Effect and Root cause analysis
  Start
- Domains of underlying root causes
  Preview
- Root cause Analysis - Example - Frame cracks
  Start
- Effects of failure and Examples
  Start
- Evaluation of Risk and and Severity levels
  Start
- Grading of severity
  Start
- Design prevention control
  Start
- Occurence
  Start
- Grading of Occurrence
  Start
- Detection control and Design verification
  Start
- Detection Grading
  Start
- Process of preparation of DFMEA
  Start
DFMEA of a Bicycle
9 Lessons
- Format
  Start
- DFMEA Bike Item 1
  Start
- DFMEA Bike Item 2
  Start
- DFMEA Bike Item 3
  Start
- DFMEA Bike Item 4
  Start
- Assigning Severity Rating to Item 1 failure modes
  Start
- Assigning Occurence ratings to Potential causes in Item 1
  Start
- Assigning Detection rating to Potential causes in Item 1
  Start
- Complete the DFMEA- Exercise
  Start
DFMEA of a Screwdriver
3 Lessons
- DFMEA of Screwdriver - Part 1
  Start
- DFMEA of Screwdriver Part 2
  Start
- DFMEA of Screwdriver Part 3
  Start
DFMEA of Hydraulic Steering System
11 Lessons
- Steering System - Introduction
  Start
- Structure Analysis - Steering System
  Start
- Boundary Diagram
  Start
- Function Analysis - Steering System
  Start
- Function Tree - Steering System
  Start
- Parameter Diagram
  Start
- DFMEA Part 1
  Start
- DFMEA Part 2
  Start
- DFMEA Part 3
  Start
- DFMEA Part 4
  Start
- DFMEA Part 5
  Start
Test your Knowledge
1 Lesson
- Quiz on DFMEA
  Start

Mufaddal Rasheed

Mufaddal Rasheed is a mechanical design engineer , inventor and online entrepreneur working towards building a comprehensive knowledge resource base for students and mechanical design professionals with focus on building skills and knowledge to design mechanical products

The goal is to build a comprehensive knowledge eco-system for mechanical design engineers and aspirants which would prepare an individual for engineering innovation and advance their careers in terms of knowledge.

Experienced professional with 7+ years experience in Automotive product development designing chassis and suspension systems and being part of multiple projects from concept to production.

He is passionate about mechanical design and innovation and writes regularly on Quora with a Top writer badge.

Core belief is that engineering is a lifelong learning process and for a designer it is "the more you know the better you design"

Working towards developing an alternate solution to the problems of engineering education and upskilling for economic growth.

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