🥇 How to Build a Suggestion System: The DFMEA Method

The article is a comprehensive guide to the DFMEA (Design Failure Mode and Effects Analysis) method, a tool used for risk analysis and identification of potential product defects already at the design stage. The author begins by explaining what FMEA is as a general prevention method, covering both existing processes and newly designed ones.

Then, it focuses on DFMEA analysis, explaining that it is a process aimed at understanding the strengths and weaknesses of the product design. Through the analysis of the product structure, a range of possible defects that may occur already at the production stage can be identified. An important element of DFMEA is the involvement of an interdisciplinary team, which, thanks to its diversity, can look at the product from different perspectives.

The article also discusses what types of defects can be detected at the design stage, including risks of product errors during operation, erroneous assessment of product actions, construction technology of the element, repair possibilities, and functions that the designed product will fulfill.

The author notes that many companies opt for online training in FMEA and DFMEA, which was accelerated by the 2020 pandemic situation. It is emphasized that applying these methods in practice, especially during Gemba workshops, brings real benefits thanks to the practical approach and utilization of the working group's potential.

At the end, the article compares DFMEA with PFMEA (Process Failure Mode and Effects Analysis), noting that DFMEA focuses on identifying potential errors in the design process, while PFMEA concerns the analysis of potential failures in the production process. It is emphasized that implementing FMEA in enterprises allows not only for ensuring safety but also for better understanding of processes through the identification of potential defects and their causes.

The article ends with an invitation to participate in stationary trainings based on practical business examples from the participants' organizations. Participants in these trainings gain basic competencies in performing DFMEA analysis, which brings tangible benefits in their further professional career. In summary, DFMEA analysis is a key tool in the dynamically changing world, enabling the prevention of product defect consequences and streamlining the production process.