DFMEA for Compressor Project to Achieve Certification and Risk Mitigation
The Way We executed the Project
Client: Leading Compressor Manufacturer
Industry: Industrial Equipment & Machinery
Services: DFMEA, Risk Mitigation, Design Optimization
Project Background
The client, a prominent manufacturer in the compressor industry, aimed to secure certification for one of their critical compressor products. To meet certification requirements and minimize the risks associated with the design, a comprehensive Design Failure Mode and Effects Analysis (DFMEA) was necessary. The goal was to identify potential failure modes, analyze their effects on the system, and implement mitigation strategies to enhance the overall reliability and safety of the compressor.
Our Scope
We were tasked with performing a thorough DFMEA for the entire compressor system, focusing on failure analysis at both the assembly and component levels. Our approach was to systematically evaluate each subsystem and individual part to predict potential failure points, assess their risk levels, and provide recommendations for design improvements to eliminate or minimize these risks.
DFMEA Approach:
- Failure Mode Identification: Conducted an exhaustive analysis of potential failure modes at the assembly, sub-assembly, and component levels, considering all operating conditions and environmental factors
- Risk Analysis (Severity, Occurrence, Detection): Evaluated the severity of potential failures, their likelihood of occurrence, and the ability to detect them, using a standardized Risk Priority Number (RPN) scale
- Root Cause Analysis: Performed root cause analysis for each identified failure mode to understand underlying issues that could impact performance, reliability, or safety
- Mitigation and Risk Reduction: Recommended design changes, material improvements, and process optimizations to reduce the risk of high-priority failure modes
- Validation and Verification: Collaborated with the client’s testing and validation teams to ensure that the implemented design changes effectively addressed the identified failure modes, ensuring compliance with certification standards
- Continuous Monitoring: Established a system for continuous monitoring and reassessment of risk as part of the product lifecycle management process
What Value Added
- Enhanced Reliability: The DFMEA process resulted in a more robust compressor design, minimizing the risk of operational failures
- Certification Readiness: Successfully identified and mitigated all critical risks, ensuring the product met the stringent requirements for certification
- Design Optimization: Improved overall product design by addressing key failure points, reducing the likelihood of breakdowns in real-world applications
- Cost Reduction: By identifying potential failure points early in the design phase, the client was able to avoid costly modifications and repairs during production or after market release
Key Outcomes
Reduction in Risk Priority Number (RPN)
40%
Certification Achieved in Record Time
100%
Increase in Product Reliability
25%
What Our Clients Appreciate
SBDC Engineering’s expertise in DFMEA has been instrumental in helping us achieve certification for our compressor project. Their in-depth analysis and clear risk mitigation strategies ensured that our product met all required standards while enhancing its reliability and performance.
Design & Development Lead, Leading Compressor Manufacturer
Partner with Us for Your Next Big Idea
Whether you’re at the concept stage or ready for production, we’re here to make it happen. At SBDC Engineering Services, we specialize in turning ideas into reality with precision, innovation, and sustainable solutions. If you’re ready to take the next step, we’d love to collaborate and bring your vision to life