Identifying the failure modes of processes, designs, and assets is a critical part of continuous improvement for manufacturers. Completing a failure mode and effect analysis (FMEA) can help companies identify and address potential failures before they cause disruptions across the plant.
But what about other types of analysis, like design failure mode and effect analysis and process failure and effect analysis (DFMEA vs. PFMEA)? This article will discuss the different types of failure mode effect analysis, what makes them unique, and when you should use each one.
What is FMEA, DFMEA, PFMEA?
While they share the words “failure mode and effect analysis,” each of these acronyms has a different meaning. Each one is important in different stages of manufacturing and product development.
A failure mode and effect analysis (FMEA), is a process where every possible failure that could happen with a piece of equipment is identified. The goal of FEMA is to identify potential failures, determine the outcomes of each failure, decide how important those failures are, and put a plan in place to mitigate the failures.
Design failure mode and effect analysis (DFMEA), specifically focuses on how a product is designed and determines how that design might fail. The purpose of DFMEA is to detect and correct potential design failures before the product is mass-produced or reaches the end user. For manufacturing, assets used in product creation or packaging may undergo a DFMEA analysis before being built or put into use.
Finally, process failure mode and effect analysis (PFMEA), looks at a process from start to finish and identifies potential failures. It can be used to analyze the entire manufacturing process for a product, or a section of that process such as product assembly or packaging. PFMEA can also be used to examine other processes that occur throughout an organization.
Differences between DFMEA vs PFMEA
There are several key differences between DFMEA and PFMEA. This table shows how they differ in scope, frequency, and application:
| DFMEA | PFMEA | |
| When they are used | During the design or redesign processes, prior to manufacturing | Before or during the manufacturing process, and as needed on an ongoing basis |
| Why they are used | To identify product design failures that could impact product quality and end user satisfaction | To identify process failures that could slow production, cause a shutdown, or result in errors in the end product |
| How often they are used | Only during the product development process, or when the product is being redesigned | On an as-needed basis when there are changes in the assets used, after a major failure that needs to be better understood, or when there are process changes |
| Who completes them | The product team, consisting of design, development, and product quality experts | Manufacturing team members, including supervisors, quality control specialists, production engineers, and other stakeholders |
| What happens with the results | Design tweaks and improvements, including changes to materials and form that improve the design and function of the product | Improvements in processes to avoid failures, such as improved maintenance practices, employee training, inspections, or others. |
When to Use DFMEA vs PFMEA
DFMEA and PFMEA are both important parts of product creation, but they should be used at different times.
DFMEA is used during the design process, but some products may require that it be completed multiple times. The initial DFMEA may be created during the preliminary design phase, and then another DFMEA may be completed before the final design is produced. If the product is redesigned for improvements or changes are made to the design based on consumer feedback, another DFMEA should be completed before the redesigned product enters production.
Similarly, a PFMEA may be completed multiple times. A manufacturing company may complete a PFMEA before ramping up production of a product to ensure it can meet quality and volume expectations. A PFMEA might also be completed after a major failure, when equipment is replaced, or when new processes are being implemented.
Which Analysis Should You Use?
If you’re still not sure whether to use a DFMEA vs. PFMEA, ask the following questions to narrow down which is best for your use case::
- Are you trying to correct problems in the product itself (DFMEA) or in the production of the product (PFMEA)?
- What stage of the product life cycle are you in? If the product is still in the design phase, use a DFMEA. If the product is being produced, use a PFMEA.
- Are the problems you want to address more related to the design (such as component failures or material weaknesses), or to the process (such as product assembly or equipment malfunctions)? If the former, use a DFMEA, and if the latter, use a PFMEA.
DFMEA and PFMEA are both important processes in product development and manufacturing. Whether you’re designing a product for mass production or improving processes throughout a manufacturing plant, a computerized maintenance management system, or CMMS, can be a useful tool for tracking and improving operations.
A CMMS can identify trends in equipment failures and processes over time and show how process or design improvements have impacted them. Such documentation is important for continuous improvement and ensuring excellent product design and manufacturing quality.
To learn more about what a CMMS can do for your team, speak with a specialist or request a free demo of eMaint CMMS.