Design Failure Mode and Effects Analysis (DFMEA) is used to identify and mitigate risk. After the system level, DFMEA is completed and the detailed hardware design is underway, a hardware level DFMEA is done. The hardware DFMEA uses a perspective of circuit failures internal to the ECU and the effects that will have on the system given the system level DFMEA. This ensures the detailed design considers the best way to make a reliable and safe product for Pi’s customers.

The hardware DFMEA identifies effects of failures to the system, including loss of functions, based on circuit failures. The causes of these failures are then identified and analyzed to determine how likely they are to occur and indicate any design changes needed to reduce the potential occurrence of failures. These causes can come from environmental conditions, manufacturing or part variation, customer usage, and lifetime degradation.

By completing hardware-level DFMEA, significant characteristics that must be managed during production, including any special test needs, are taken into consideration. These significant characteristics are passed to the manufacturing facility for their PFMEA/control plan.

The entire DFMEA process allows Dana to develop a high-quality and safe product.