Professional Documents
Culture Documents
Re-shaping Design
dFMEA 2014
References (TBD)
Deductive Analysis ref ISO18
C_044_BRK_3_001_289_EN
QS-9000: FMEA Fehler-Mglichkeits- und -Einfluss-Analyse,
VDA: VDA-Band 4 Sicherung der Qualitt vor Serieneinsatz Produkt- und Prozess-FMEA, 2. Auflage, 2006
DIN EN 60812
DGQ: Band 1311 FMEA Fehlermglichkeits- und
Einflussanalyse, 3. Aufl. 2004,
dFMEA 2014
Functions
Failures
Actions
dFMEA 2014
ECU Requirements
ECU Architecture
RANDOM COMPONENT
FAILURE RISK
REDUCTION
SYSTEMATIC
DESIGN FAILURE
RISK REDUCTION
SPFM/LFM
ECU Schematics & Layout
dFMEA
dFMEA 2014
Occurrence (O)
Severity (s)
Detection(D)
D-FMEA shall reduce the risk for
systematic failures (design failures, Risk Priority Number (RPN
Experience
tests
e.g. wrong component selected,
simulation
tolerances not considered,
Worst case analysis
temperature influence not considered)
/ Drift
Its NOT required to use the D-FMEA Open / Short Pin-to-Pin
failures
for random failures, e.g. resistor open
FIT-RATE
due to random failures. Use the SPFMSingle Point Fault Metric (SP
LFM analysis to reduce the risk for Latent Fault Metric (LFM )
random failures and to ensure that the
FRC Criteria
Diagnostic Coverage is high enough.
DC
dFMEA 2014
Element Structure
Structure
Functions
Failures
Actions
1
2
Component folder to support linking to pFMEA (not necessary for completion of dFMEA)
Example 1)
Example 2)
2
2
dFMEA 2014
Functions
Failures
Actions
dFMEA 2014
a)
b)
Functions
Failures
Actions
Example 2)
Block,hardware,physical
Block,hardware
O urECU
PowerSupplyInterfaceHw
Operations
ProvideEpbSupplyVoltage
KL30_P
KL30_V
PumpMotSupVoltSig
ProvideSupplyGndVoltage
PumpMotSupGndSig
GND_V
GndSupVoltSig
EpbSupVolt
GndSupVolt
SolSupVoltSig
GND_P
Block,hardware
Block,hardware
EpbMotorInterfaceHw
Block,hardware
EpbSecondMicro
MicroController
Operations
DriveEpbMotor
ProvideEpbMotorVoltFeedback
GndSupVolt
ProvideEpbMotorElecCurrFeedback
EpbSupVolt
1
1
hardware,ASI L Bof D
EpbHbridgeDrvSig
EpbHbridgeDrvSig
EpbHbridgeDrvSig
software,ASI L Bof D
itsEpbControlSw
itsInOutControllerHw
EpbMotHbridgeDrvCtrl
ProvideEpbMotActuation
software,ASI L Bof D
itsSpiControllerSw
Operations
M anageEpbFailSafe
M onitorEpbMotorCurrent
Operations
ActuateEpbMotHbridgeDrvSig
EpbActuCmd
SpiData
EpbMotStateExtended
SpiCtrl
hardware,ASI L Bof D
itsSpiControllerHw
hardware,ASI L Bof D
itsSpiControllerHw
Operations
HandleEpbActuCmd
HandleEpbMotStateExtendedVal
Operations
SendSpiSignal
Operations
software,ASIL BofD
software
itsSpiDriverSw
itsApplicationSw
Operations
Operations
HandleEpbActuCmd
ReceiveSpiSignal
SendSpiSignal
ReceiveSpiSignal
SpiSig
SpiSig SpiSig
SpiSig
SpiData
EpbActuCmd
ParkBrake
SpiC trl
EpbMot1ActuSig
b)
EpbActuatorHs
EpbMotVoltFbkSig
EpbMotVoltFbkSig
EpbMotVoltFbkSig
EpbElecCurFbkSig
EpbElecCurFbkSig
EpbElecCurFbkSig
hardware,ASI L Bof D
itsADSignalConversionEpbHw
Operations
SampleEpbM otorFeedback
SampleEpbElecCurrentFeedback
EpbMotVoltFbk
EpbMot2ActuSig
EpbElecCurFbk
EpbActuatorLs
dFMEA 2014
Functions
Failures
Actions
The Components3 are the link to the pFMEA (not necessary for completion of dFMEA)
Shows WHICH components PROVIDE the function
A failure of the components leads to a failure in the function.
A further break down to single component failures is not necessary as the Engineering detection actions verify the
function
Mission Critical elements (shunts, processors) shall be treated as Main Architecture elements
100% component failure break down is analysed during the SPFM/LFM
Example 2)
dFMEA 2014
Functions
Failures
Actions
Example 1)
1
1
dFMEA 2014
10
Failure Nets
Structure
Functions
Failures
Actions
dFMEA 2014
11
Functions
Failures
Actions
Example 1)
dFMEA 2014
12
Actions
Structure
Functions
Failures Actions
Example 1)
dFMEA 2014
13
Severity Rating
Structure
Rank
10
Criteria
Loss or degradation of
primary function
Loss or degradation of
Secondary function
5
4
Loss of primary function (Vehicle inoperable Stopper, does not affect safe
vehicle operation, vehicle needs direct service).
Degradation of primary function (Vehicle operable, but at a reduced level of
performance).
End-user very dissatisfied.
Unable to assemble or parametric reject at Vehicle Manufacturer (VM) or VM's
module sub-contractor.
Annoyance
Failures Actions
Effect
9
8
Functions
No effect
No discernible effect
dFMEA 2014
14
Rank
Functions
Failures Actions
Likelihood
Description
Example
10
Very Persistent
failures (Almost)
Very Persistent
failures (High)
Frequent failures
(High)
dFMEA 2014
15
Rank
6
Description
Example
Occasional failures
(moderate)
Failures Actions
Likelihood
Functions
Unlikely
16
Rank
Functions
Failures Actions
Likelihood
Description
Example
10
Absolute
Uncertainty
Very
Remote
Remote
Very Low
Low
dFMEA 2014
17
Functions
Failures Actions
Rank
Likelihood
Description
Example
Moderate
Moderately
High
High
Very High
Certain
dFMEA 2014
18
dFMEA 2014
19
dFMEA 2014
20
[1] http://skobde-mks.kobde.trw.com:7001/si/viewrevision?
projectName=/CircuitLibraryRepositories/59322912%5fCircuitLibraryDevelopmentFram
ework/03%5fTemplates/10%5fReviewTemplates/project.pj&selection=593XXXXX
%5fCLICDApprovalReviewNIssueM.docx
dFMEA 2014
21
PREVENTION
(reduce Occurrence)
GEE SysE
HW Requir.
ECU Electronics
Design FMEA
Structure
Functions
Failures Actions
DETECTION
Dedicated Reliability
Tests
ECU Architecture
Description incl. Safety
CL interface definition /
requirements / profiles
Circuit Library
Tests
CL Electrical Test
CL Design Spec.
CL Functional Test
Design Rules
ECU Fault Injection Tests
for ECU internal failures
Circuit
Library
Req.
& Analysis
Simulation Report
Review Report
SW Interface Control
Document (ICD)
EMC Test
Test Requirements
Document for
Production Tests
Thermal shock
xxx
(TRD)
Application
DV/PV
LV124 Tests for
Electronic &
Hydraulic
xxx
TRW Automotive 2014
dFMEA 2014
22
Statistics
Structure
Functions
Failures Actions
10
9
8
7
6
5
4
4/4
3
2
1
O/D
dFMEA 2014
23
Functions
Failures Actions
dFMEA 2014
24
Attachment
D-FMEA vs. SPFM/LFM
dFMEA 2014
25
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D-FMEA
SPFM/LFM
dFMEA 2014
26
D-FMEA
SPFM/LFM
D-FMEA
Plan
51,00%
22,00%
17,00%
5,00%
5,00%
MIL HBK
338B
dFMEA 2014
27
D-FMEA
SPFM/LFM
TRW
APIS IQ FMEA
.xls Template
dFMEA 2014
28