Design FMEA (DFMEA) — AIAG-VDA 2019

Goal

Identify and mitigate design risks by analysing functions, interfaces, and failure modes — so that design weaknesses are resolved before release to manufacturing, and the results feed directly into the DVP, PFMEA, and Control Plan.

Required Execution Checklist

• DFMEA scope defined: boundary diagram complete, inside/outside boundary identified
• Product hierarchy mapped: system → subsystem → component → interface (Step 2)
• All interfaces identified — internal (component-to-component), external (environment), and user/assembly
• All functions defined with Verb + Noun + Measurable Standard (Step 3)
• Each function has a measurable verification method confirmed in the DVP
• Failure chain complete: Effect → Mode → Cause for each function (Step 4)
• All Failure Causes validated using engineering analysis (FEA, calculation) or test evidence — not assumptions
• S/O/D ratings justified using analysis, test data, or design history
• All H-AP items have a defined action, named owner, and target date
• DFMEA → DVP, PFMEA, and drawing linkage verified before release to manufacturing