7FM Design Failure Mode and Effects Analysis Training Length - 2 Days
7FM DFMEA methods exceed SAE, VDA, and AIAG requirements. 7FM rationalizes functions, their sequence, and requirements. Functions are optimally designed from the start. The analysis produces optimal designs. The 2017 Chrysler Pacifica was the first full vehicle to complete this process. The Pacifica Design took three years, concept to production. Its quality was 60% better than any vehicle in its class, including Toyota. The PHEV and full powertrain were included (software and hardware). The Pacifica is the most award-winning vehicle in its class every year since launch.
The PHEV has remained in the top three since launch.
- Understanding the Function and Overview of DFMEA.
- Requirements, the function, types of function, physics of
the function, hierarchy of the function, sequence, and primary functions. The 7FM DFMEA workbook.
Three levels of 7FM DFMEA
- Component level DFMEA.
Component function architecture, how energy, materials, dimensions,
contact/relative relationships make the component work, function definition,
- Assembly level DFMEA.
Assembly function architecture to describe how components work together
to produce assembly primary functions.
Assembly function definitions, requirements, and specifications.
- System level DFMEA.
System function architecture to describe how assemblies work together to
produce the system’s primary functions. System function definitions,
requirements, and specifications
- Types of functions, active, reactive, passive, information,
command requests, and energy
- The functional block diagram and functional agreement from
start to stop
- The seven failure modes and their temporal sequence of
following failure modes leading to a clear temporal fault states map.
- Cause and Effects Analysis.
The fault state map and the physics of the function (energy, structure,
resistance, and losses) lay the causes, failure mode, and effects flat. Factors that degrade the function
(temperature, vibration, chemicals, debris, radiation, etc.) are included in
the analysis so show how they degrade design parameters.
- Controls, Risks, and Improvements
- Prevention and Detection.
Prevention works on design parameters to reduce the risk that they will
change and become a cause of function failure.
Degradation factors determine which of 5 mitigation strategies should be
used to prevent or significantly delay their degradation of parameters. Detection is used for testing to ensure no
gross design oversites have been made.
Detection covers function capability, fault injection, degradation, and
test to failure.
- System Fault Detection and Mitigation. Using sensors or calculations from a control
module/computer to detect function faults and to use controls to mitigate severity
- Risks. Understand the
severity of effect, the criticality of the failure mode (severity and frequency
of occurrence), and why the Risk Priority Number (RPN) is a weak risk number
- DVP&R Effective testing: Function Performance, Function
Degradation, Function Failure.
- Recommended actions.
Removing Risks from the design