Design Process Error Proofing: Failure Modes and Effects Analysis of the Design Process

[+] Author and Article Information
Lawrence P. Chao

Digital Health Group, Rotation Engineers Program, Intel Corporation, Santa Clara, CA 95054chaol2@asme.org

Kosuke Ishii

Department of Mechanical Engineering, Design Division, Stanford University, Stanford, CA 94305-4022ishii@stanford.edu

J. Mech. Des 129(5), 491-501 (Jul 19, 2006) (11 pages) doi:10.1115/1.2712216 History: Received November 10, 2005; Revised July 19, 2006

This paper presents a new application of failure modes and effects analysis (FMEA) on design processes. Our research develops error-proofing methods for the product development process to prevent serious design errors that can compromise project features, time to market, or cost. Design process FMEA is a systematic method which allows product development teams to proactively predict potential problems. The method decomposes the design process into six potential problem areas—knowledge, analysis, communication, execution, change, and organization errors—with a question-based FMEA approach. The paper explains the method, illustrates it through a case study, and discusses its effectiveness. The paper concludes with the proposed work to address design process error-proofing solutions.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 6

ASV task importance scores derived from QFD matrices relating design tasks to parts (QFD-III*) and engineering metrics (QFD-II*)

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Figure 1

Calculation of risk priority number for FMEA

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Figure 2

Key factors mapped on to a task

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Figure 3

Using QFD matrices to rank design tasks

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Figure 4

Using QFD matrices to rank design errors

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Figure 5

The adaptive suspension vehicle



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