Live Tool
DFMEA setup
Formula: RPN = Severity x Occurrence x Detection (1-10 each)
Score Severity, Occurrence, and Detection on a 1-10 scale, per standard FMEA convention.
Calculator Library / Design Risk Analysis
DFMEA Builder
Score design failure modes by Severity, Occurrence, and Detection, and let the tool calculate RPN and rank every failure mode by priority. Built for the Design phase, the counterpart to the site's Process FMEA tool.
Editable Worksheet
Design failure modes
| Function | Failure Mode | Effect | S | Cause | O | Current Controls | D | Recommended Action |
|---|
Preview
Design FMEA
| Failure Mode | Effect | S | O | D | RPN | Recommended Action |
|---|
How to Use This DFMEA Builder
List each design function, then identify how it could fail, the effect of that failure, and its root design cause. Score Severity, Occurrence, and Detection from 1 to 10 using your organization's FMEA scoring guide. The tool calculates RPN automatically and sorts the preview by priority so the highest-risk items surface first.
RPN Priority Guide
| RPN Range | Priority |
|---|---|
| 200 and above | High: address before design release |
| 100-199 | Medium: plan a design or verification action |
| Below 100 | Low: monitor, revisit if design changes |
Export and Print Options
Use Print / Save PDF to open the browser print dialog and save the finished DFMEA as a PDF. Use the Word and Excel buttons when you need an editable file for Microsoft Office. Use the Google Doc and Google Sheet buttons when you need a file that can be uploaded or imported into Google Drive.
FAQ
What is a DFMEA?
A Design Failure Mode and Effects Analysis (DFMEA) evaluates a product design for potential failure modes before it goes into production, scoring each one by Severity, Occurrence, and Detection to prioritize design changes.
How is a DFMEA different from a PFMEA?
A DFMEA evaluates failure modes caused by the design itself, such as insufficient material strength or tolerance stack-up. A PFMEA evaluates failure modes caused by how the product is manufactured or assembled.
How is RPN calculated?
Risk Priority Number (RPN) equals Severity multiplied by Occurrence multiplied by Detection, each scored 1 to 10, giving a range of 1 to 1000. Higher RPN means higher priority for design action.
When should a DFMEA be completed?
Complete a DFMEA during the design phase, before tooling or production commitments are made, so failure modes can still be designed out rather than caught in production.