DFMEA Quiz

What is DFMEA and why is it important?

• A cost reduction tool used only in manufacturing

• A reliability analysis for identifying and preventing design failures

• A financial risk management method

• A customer complaint tracking system

How is VDA DFMEA different from AIAG DFMEA?

• VDA uses Action Priority, AIAG uses RPN

• VDA ignores severity, AIAG includes it

• AIAG focuses on visuals, VDA on checklists

• Both are identical

What is the 7-step approach in DFMEA?

• Planning → Design → Prototype → Test → Review → Release → Audit

• Planning → Structure → Function → Failure → Risk → Optimization → Documentation

• Design → Failure → Test → Correction → Validation → Delivery → Service

• Concept → Build → Validate → Approve → Launch → Service → Retire

Why did VDA move from RPN to AP?

• RPN was too easy to calculate

• RPN sometimes hid critical high-severity risks

• AP is faster to compute than RPN

• Customers demanded it

How do you ensure DFMEA is a living document?

• Prepare once and file for audits

• Keep updating with design changes and lessons learned

• Use only for PPAP submission

• Restrict it to the quality department

How do you define the scope of DFMEA?

• By selecting only customer complaints

• By identifying system, boundaries, interfaces, and lifecycle phases

• By manufacturing cost only

• By warranty returns only

Who should be in a cross-functional DFMEA team?

• Only designers

• Design, manufacturing, quality, supplier, service teams

• Only customer representatives

• Only management

What is a structure tree in DFMEA?

• A reliability growth chart

• A diagram showing system → subsystem → component hierarchy

• A cost breakdown

• A supplier list

What is a function net?

• A tool to link functions, failures, and causes visually

• A design release checklist

• A testing protocol

• A supplier audit form

What is the difference between effect, mode, and cause?

• Mode = what failed, Effect = impact, Cause = reason

• Mode = reason, Effect = what failed, Cause = impact

• All three mean the same

• Mode = solution, Effect = cause, Cause = detection