North America

Red Room - Session 2

1:00 to 2:00 p.m. Tuesday, June 13, 2017

Linking 8D Problem Solving to Improving the DFMEA Process

Each post-DFMEA design change can be thought of as a "miss" in the DFMEA analysis.

Effective use of 8D (Step 7 "Prevention") is a source to identify gaps and opportunities to improve the FMEA facilitation process.  Most problem solving teams will review the relevant DFMEA and discover either: a) Function was not included, b) Failure Mode not included, c) Noise Factor missed, etc., then proceed to update the document for that specific new discovery and close the 8D.

This discussion will put forward a method of improving the facilitation of future DFMEAs to better capture a complete list of Functions, Failure Modes and particularly Noise Factors that have proven to have been overlooked in past DFMEA events.

As with any process, the first step to improving quality is to take as much variation as possible out of the process (i.e., create as much repeatability as possible in the process). My experience is that Boundary Diagrams and P-Diagrams do provide sufficient repeatability to apply this technique.

We will examine an example of 10 field product improvement projects, each of which implemented a design change, review the DFMEA "misses," and identify facilitation techniques/topics intended to better capture the "blind spots" of the previous FMEA team.

Key Words: DFMEA, 8D Problem Solving, Prevention, Boundary Diagram, P-Diagram, Cost Avoidance, Continuous Improvement, Lessons Learned.

David Ruether

John Deere

Dubuque, Iowa