Ensuring Zero Defects Through Effective Design Failure Modes and Effects Analysis Processes in the Aerospace Industry

The Aerospace Industry's drive towards zero defects has seen a significant shift to prevent defects and improve product quality during the design phase, instead of waiting until post-production inspection to discover and troubleshoot problems. Trying to ensure zero defects during the post-production inspection phase is too late in the product life cycle because it can lead to substantial costs. Aerospace Engine Supplier Quality (AESQ) introduced the Advanced Product Quality Planning (APQP) [2] process to realize zero defects. In APQP Phase 2 [2], Product and Design Development, a key output is performing a Design Failure Modes and Effects Analysis (DFMEA). Moog has effectively implemented a DFMEA process that adeptly identifies and mitigates design risks. This work showcases Moog's successful deployment of DFMEA, exemplifying the industry best practices. This work also presents simplified and innovative interpretations of DFMEA definitions and approaches. By addressing defects during the design phase, the resulting product design optimizes performance, achieves higher reliability, and may also minimize waste and promote sustainability.