Design FMEA

Design FMEA is a structured approach that ensures potential failure modes and their associated causes have been considered and addressed in the product design. It identifies design functions, failure modes and their effects on the customer with corresponding severity ranking/danger of the effect.

Design FMEA

Course Objective

To gather potential causes by which a product design can fail.

Learn to make our design more robust.

Define the Design FMEA scope.

Conduct the ranking scales for Severity, Occurrence, and Detection.

Make the Design FMEA into an active document.

Develop correct parameters based on Design FMEA.

Who Should Attend

Manufacturing Managers

New Product Development Managers

Quality Engineers and Managers

Plant Engineers

Management Representative

Technical Staff

Quality Professionals

Suppliers Quality Assurance

Maintenance Manager

Benefits of Attending

The Design FMEA procedure is a highly effective way to evaluate the design of the products. It is as valuable for revealing areas needing improvement as it is for guiding the development of new designs.

  • Help Identifying potential failure modes of the product ranked according to their effect on the customer; establishes a priority system for design improvement and development testing while still in the design phase
  • It increases the probability that potential failure modes and their effects on the system/product have been considered.
  • Provides an open issue format for recommending and tracking risk-reduction actions.
  • It aids in analyzing field concerns, design changes and in developing advanced designs.
  • It helps to standardize ranks to the potential failure modes according to their effect on the customer, thus help in prioritizing improvements.

One of the most critical benefits is that it specifies certain activities that will certainly help to prioritize the design failures of a product.

Workshop Agenda

Introduction to Design FMEA

Design FMEA Information Flow

Inputs to Design FMEA

Introduction to Robustness Tools (Robustness Linkages)

Boundary Diagram

Interface matrix

P- Diagram

Potential Failure Modes

How to identify failure Mode Types.

Sample Functions and Failures

How to identify Potential Failure Modes

Functional Approach

Potential Effects of Failure

Potential Effects of Failure

How to identify Potential Effects of Failure

Examples of Potential Effects of Failure


How to identify Severity Rating,

Design Severity Rating Table



YC Classification Rating

Potential Cause(s)/Mechanism(s) of Failure

Potential Cause(s)/Mechanism(s) of Failure

How to Identify Potential Cause(s) of Failure


How to Identify Occurrence

Occurrence Rating Table

Current Design Controls

Types of Design Controls

How to Identify Design Controls


How to Identify Detection Rating

Effectiveness Factors

Design Detection Rating Table

Risk Priority Number (RPN)

Calculate Risk Priority Number

Fault Tree Analysis

Understanding the symbols and solve problems

Training Deliverables

Feedback From Past Participants

This workshop has helped us in prioritizing the design failures”

“Our product Design capability has improved significantly”

“ I think the tool is very necessary for improving the product design”

“It is useful for all manufacturing companies”

“The exercises were very helpful for clear understanding of how to design products”

Know Your Trainer


B tech from NIT Rourkela, PGDM  from IIM Calcutta with 14+ yrs of intensive experience in various sector. He is a certified coach for Manufacturing Management and System Development

He has helped companies turn-around by implementing Manufacturing Excellence through Lean, Statistical Quality Control, Six Sigma, Strategy Management

He is a passionate reader and have inclination to solve complex business problems within very short span of time.

@Tetrahedron Manufacturing Services Pvt Ltd

Phone : +91 7042140046         Email:

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