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Prerequisites

  • System Element (component or subsystem) defined in the project
  • Design Requirements and/or Characteristics identified for the target element
  • Optional: Upstream System FMEA document to link cascading failure modes

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Steps

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1. Navigate to the Risks Space

From the sidebar, click Risks or navigate to the Risks space dashboard. This is where all risk analysis documents (HARA, FMEA, Control Plans) are stored.

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2. Create New Document

  1. Click Create Document in the Risks space
  2. Configure the document properties:
    • Type: Select riskSpecification
    • Title: Follow naming convention: <System Element> - Component DFMEA (e.g., “Camera Module - Component DFMEA”)
    • Template: Select DFMEATemplate from RiskTemplates space
    • Custom Fields:
      • systemElement: Link to the component or subsystem being analyzed
      • documentType: Set to “Component DFMEA” or “Subsystem DFMEA”

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3. Configure Risksheet Integration

After document creation, configure it to open in Risksheet:
  1. Open the document in edit mode
  2. In the Document Properties panel, enable Use Risksheet
  3. Select the DFMEA risksheet configuration (automatically applied from template)

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4. Open in Risksheet

Click Open in Risksheet to launch the interactive DFMEA editor. The DFMEA uses a progressive workflow with 9 named views:
ViewPurpose
1. Scope DefinitionDefine items/requirements to analyze
2. Failure IdentificationAdd failure modes
3. Effects AnalysisDocument failure effects
4. Causes AnalysisIdentify failure causes
5. Current ControlsList existing prevention/detection controls
6. Risk AssessmentRate Severity/Occurrence/Detection (SOD)
7. Action PriorityCalculate Action Priority (H/M/L)
8. Mitigation PlanningDefine recommended actions, link risk controls
9. Post-MitigationTrack residual risk after controls implemented

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5. Define Analysis Scope (View 1)

In the first view, define what you’re analyzing:
  • Design Requirement or Characteristic: The design element being assessed
  • System Element: Auto-populated from document custom field
  • ASIL: If inherited from safety goal/requirement
For component DFMEA, organize by characteristics (e.g., “Voltage Range”, “Response Time”).
For subsystem DFMEA, organize by functions or design requirements.

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6. Add Failure Modes (View 2)

For each design element, create child failureMode work items:
  1. Click Add Failure Mode in the risksheet toolbar
  2. Set Title using the pattern: <Element> - <Failure Type> (e.g., “Voltage Regulator - Output Voltage Out of Spec”)
  3. Description: Detailed failure mode explanation
  4. Link to parent design requirement or characteristic using assesses link role

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7. Assess Risk (Views 3-6)

Progress through the workflow views to complete risk assessment:
  • View 3 (Effects): Document what happens when failure occurs (impact on system, hazards triggered)
  • View 4 (Causes): Root causes (design defects, tolerances, environmental factors)
  • View 5 (Controls): Existing controls (design reviews, simulations, margin analysis)
  • View 6 (SOD Rating):
    • fmSeverity (1-10): Impact severity per AIAG-VDA scale
    • fmOccurrence (0-10): Likelihood of cause occurring
    • fmDetection (0-10): Likelihood of detecting failure before customer impact

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8. Calculate Action Priority (View 7)

TestAuto2 automatically calculates Action Priority using AIAG-VDA 2019 methodology: 
Action Priority = f(Severity, Occurrence, Detection)
  High (H):   Requires immediate action
  Medium (M): Action recommended
  Low (L):    Monitor during routine reviews
The formula is configured in the DFMEA risksheet JSON and uses automotive industry thresholds (not simple RPN).
DFMEA uses Action Priority (H/M/L) per AIAG-VDA 2019, NOT Risk Priority Number (RPN).
RPN is only used in Process FMEA (PFMEA). Do not confuse the two methodologies.
For failure modes with High or Medium Action Priority:
  1. Create or link riskControl work items
  2. Link controls to failure modes using mitigates link role
  3. Set control type: Prevention Control (PC) or Detection Control (DC)
  4. Document control description, responsible party, target date

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10. Track Post-Mitigation Risk (View 9)

After implementing controls:
  1. Re-assess SOD ratings with controls in place
  2. Set postmitigationSOD custom fields
  3. TestAuto2 auto-calculates postmitigationAP using the same formula
  4. Verify Action Priority reduced to Low or Medium
If this DFMEA addresses failure modes cascading from System FMEA:
  1. In the failure mode work item, use refines link role
  2. Link to parent System FMEA failure mode
  3. This creates hierarchical FMEA traceability (System → Subsystem → Component)
See Link to Upstream SFMEA for detailed steps.

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12. Submit for Review

Once DFMEA analysis is complete:
  1. Save the risksheet (all work items auto-saved)
  2. Close Risksheet and return to document view
  3. Set document workflow status to In Review
  4. Add reviewers and submit for approval
See Submit Document for Review.

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Verification

You should now see:
  • DFMEA document listed in Risks space dashboard with work item count
  • Failure modes visible in Risksheet with color-coded Action Priority badges:
    • H (red) for High
    • M (orange) for Medium
    • L (green) for Low
  • DFMEA Coverage Report showing percentage of failure modes with post-mitigation assessment
  • System DFMEA Report dashboard including your new document in inventory table

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Common Pitfalls

Every DFMEA document MUST have the systemElement custom field set.
Without it, the document won’t appear in component-filtered reports or the System Structure Navigator.
DFMEA analyzes design failures (wrong design, tolerance issues, material selection).
PFMEA analyzes process failures (manufacturing defects, assembly errors).
Use failureMode for DFMEA, processFailureMode for PFMEA — do not interchange.
For characteristics marked as Special Characteristics (SC) or Critical Characteristics (CC), ensure DFMEA failure modes are linked.
The Traceability Report tracks SC/CC → Failure Mode coverage as a key compliance metric.

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See Also