PPAP deliverable guide

How to complete Design FMEA (DFMEA)

The DFMEA documents how the product design could fail to meet its intended functions. It supports design risk reduction and communicates design-related characteristics and risks to process development.

Complete the fields

Item or focus element
Identify the system, subsystem, component, interface, or design feature being analyzed. In a traditional form this is often the Item or Function column; in AIAG/VDA it is established through the structure analysis.
Function or requirement
State what the item must do and the condition or target it must meet. Include interfaces and operating conditions. “Bracket” is not a function; “supports a 20 kg load without permanent deformation” is.
Failure mode
State how the intended function could be lost or degraded: for example, leaks, cracks, has insufficient torque, or has incorrect output. Do not write the cause in this field.
Potential effects of failure
Describe the consequence at the next level, vehicle, manufacturing operation, or end user. This is where Severity is evaluated in a traditional template.
Potential causes or mechanisms
State the specific design reason the failure can occur, such as inadequate wall thickness, incompatible material, tolerance stack-up, or insufficient thermal margin.
Current prevention and detection controls
Prevention controls reduce the chance of the cause; detection controls identify a design weakness. Cite the actual analysis, review, calculation, test, or validation activity.
Risk evaluation and action
Use the required organization or customer method. Traditional forms commonly show Severity, Occurrence, Detection, and RPN. AIAG/VDA uses the seven-step method and Action Priority; do not mix methods without an approved procedure.
Recommended action, owner, and evidence
Write a specific action, accountable owner, due date, and completion evidence. After implementation, reassess the affected risk using the approved method.

Step-by-step completion sequence

  1. Define the scope, design boundary, interfaces, requirements, and assumptions.
  2. Perform structure, function, and failure analysis with design, manufacturing, quality, service, and supplier input as applicable.
  3. Document prevention and detection controls that exist today; do not claim planned controls as implemented.
  4. Prioritize actions using the required methodology and reduce risk through design changes where possible.
  5. Release the updated DFMEA, communicate relevant characteristics to PFMEA and Control Plan owners, and control later design changes.
PPAP control point: The customer’s current submission request, customer-specific requirements, and approved forms control. This guide explains a practical way to prepare the record; it does not authorize a substitute format or acceptance criterion.