Design Failure Mode Effect Analysis – Concepts & Practice

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Learn about the fundamentals of preparing DFMEA for Mechanical design engineers

What you’ll learn
Why do we prepare DFMEA?
What are failure modes in mechanical design and how do we define them ?
What are root causes & mechanisms? how to find root causes for failure modes ?
What is Severity, Occurence and Detection of Failure ?
Grading of Severity , Occurrence and Detection ratings
What is Boundary or B diagram ? How to develop it with examples
What is Parameter Diagram or P diagram ? How to develop it with examples
Examples with simple mechanical products
DFMEA process walk-through and exercises
Requirements
Course is best understood with a basic prior understanding of mechanical design engineering as it is primarily directed towards design engineers already designing systems
Description
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 DFMEADefining failure modesCause and Root cause analysis using Fishbone diagramsEvaluation of Risk – Severity, Occurence and DetectionWhat is Design prevention control and Design detection control / Design verification Grading of severity, occurence and detectionThe systematic process of DFMEAWhat is B diagram and how to prepare B diagram with multiple examplesWhat is P diagram and how to prepare P diagram with multiple examplesDFMEA 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.

Overview

Section 1: Introduction

Lecture 1 Introduction

Lecture 2 Risks associated in Mechanical design and need for DFMEA

Lecture 3 What DFMEA accomplishes

Section 2: Basics of DFMEA

Lecture 4 Defining Failure modes

Lecture 5 Mechanical Phenomena of failure modes

Lecture 6 Cause , Effect and Root cause analysis

Lecture 7 Domains of underlying root causes

Lecture 8 Root cause Analysis – Example – Frame cracks

Lecture 9 Effects of failure and Examples

Lecture 10 Evaluation of Risk and and Severity levels

Lecture 11 Occurence

Lecture 12 Design prevention control

Lecture 13 Detection control and Design verification

Lecture 14 Grading of Occurence

Lecture 15 Detection and its Grading

Lecture 16 Grading of severity

Lecture 17 Process of preparation of DFMEA

Section 3: Boundary Diagram

Lecture 18 B diagram and Example of Bike

Lecture 19 B diagram Wrench

Lecture 20 B diagram Scissor jack

Lecture 21 External B diagram Seat Belt system

Section 4: Parameter Diagram

Lecture 22 P Diagram , example of a bracket

Lecture 23 Why P diagram ?

Lecture 24 P diagram details and Noise Factors

Lecture 25 Input , Output, , Control parameters definitions

Lecture 26 P diagram of Wrench

Lecture 27 P diagram of Scissor Jack

Lecture 28 P diagram of Bike

Section 5: DFMEA of a Bicycle

Lecture 29 Format

Lecture 30 DFMEA Bike Item 1

Lecture 31 DFMEA Bike Item 2

Lecture 32 DFMEA Bike Item 3

Lecture 33 DFMEA Bike Item 4

Lecture 34 Assigning Severity Rating to Item 1 failure modes

Lecture 35 Assigning Occurence ratings to Potential causes in Item 1

Lecture 36 Assigning Detection rating to Potential causes in Item 1

Lecture 37 Complete the DFMEA- Exercise

Section 6: Test your knowledge

Section 7: Bonus Section

Lecture 38 Bonus : More resources for learning Mechanical design

Mechanical design engineers who are into product development,Students aspiring to be mechanical design engineers

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