Modified DD2977 as alternative to FMEA
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Speaker : WILLIAM LEVINSON
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When : Tuesday, July 08, 2025
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Time : 01 : 00 PM EST
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William A. Levinson, P.E., FASQ, CFPIM is the principal of Levinson Productivity Systems, P.C. and the author of several books on quality, productivity, and management.
The Automotive Action Group's and VDA's relatively new (2019) Failure Mode Effects Analysis manual is probably the best and most advanced approach available. It assigns occurrence and detection ratings for failure modes based not on probabilities of occurrence, which are often hard to quantify, but rather on the nature of the prevention and detection controls in the process. It also replaces the risk priority number (RPN) with an Action Priority.
If however FMEA is overly complex and time-consuming for planning purposes, the Army's DD2977, Deliberate Risk Assessment Worksheet, will often meet an organization's needs. It is in the public domain as a publication of the US Government, and the entire document including the instructions fits on three pages. The most recent version (November 2024) is available here. https://www.esd.whs.mil
Directives/forms/dd2500_2999/DD2977/ This webinar will show how to use DD2977 to accomplish most of what FMEA will do.
Attendees will receive a pdf copy of the slides and accompanying notes.
Learning Objectives
- AIAG/VDA (Verband der Automobilindustrie) FMEA Handbook (2019) contains the latest and most advanced FMEA process, but many organizations do not feel a need to perform extensive FMEAs. The FMEA process requires an entire manual; DD2977 has one page of instructions. DD2977 may therefore be adequate for relatively simple administrative and product/service realization processes, especially when the customer does not require FMEA.
- Overview of the AIAG/VDA FMEA process for comparison
- DD2977 Process
- The Modified DD2977; how the DD2977 process corresponds to FMEA. For example, the "Hazard" corresponds to failure analysis in FMEA. Consider the failure mode (what happens that shouldn't, or doesn't happen that should), the failure cause (formerly the failure mechanism), and the failure effect (consequence of the failure). What controls, if any, are present to disable the failure causes?
- Severity correspondence between FMEA and DD2977
- Occurrence/probability correspondence between FMEA and DD2977
- Detection/probability correspondence between FMEA and DD2977, and recommended table for conversion.
- As with FMEA, what controls will reduce the risk associated with the activity?
- Occupational health and safety case study (real world example, used to illustrate DD2977)
- Shigeo Shingo, manufacturing case study, used to illustrate DD2977
Disclaimer: no part of this presentation constitutes formal engineering advice.
Who Should Attend
Quality managers, engineers, and technicians, and others with responsibility for advanced quality planning (AQP) or PPAP.
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$199.00
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