You’ve gone through the entire 7-step DFMEA process — from scoping the item to evaluating and reducing risk.
Now, in Step 7: Results Documentation, it’s time to:
“Compile, communicate, and record the DFMEA findings for decision-making, audits, and future reuse.”
This step ensures the DFMEA becomes a living document that’s:
- Ready for customer reviews
- Integrated with validation and production planning
- Used for future product improvements
🎯 Objective of Step 7 #
“Summarize key DFMEA results, risk status, remaining open actions, residual risks, and lessons learned in a format suitable for communication and audit.”
🚗 Case Study: EWP DFMEA – What to Document #
Let’s continue with the Electric Water Pump (EWP) case study and walk through how to document the results.
📑 1. DFMEA Summary Table #
The Summary Table gives a snapshot of:
- Item status
- Open High/Medium AP issues
- Residual risks
- Special characteristics
- Final approvals
Example – EWP Summary Table
| Field | Content |
|---|---|
| Item | 12V Electric Water Pump |
| System | Vehicle Thermal Management |
| Scope Covered | Mechanical, electrical, sealing, EMC interfaces |
| Total Functions Analyzed | 17 |
| High AP Items (Open) | 0 |
| Medium AP Items (Open) | 1 (under closure) |
| Low AP Items | 12 |
| Residual Risk Accepted By | Chief Engineer |
| Special Characteristics | 2 Safety (🔺), 1 Regulatory (🔧) |
| DFMEA Owner | John Smith (Quality Engg.) |
| Revision & Date | Rev 2.1, Dated 06-Sep-2025 |
📥 Template available for download (Excel/PDF)
📋 2. Residual Risk Statement #
If any risks remain (typically Medium AP), they must be clearly documented and approved.
Example:
Residual Risk: Shaft-to-impeller retention still carries AP = M despite spline update.
Justification: Retention torque margin increased by 60%, verified via testing.
Accepted By: Chief Engineer (signed 02-Sep-2025)
Plan: Monitor through validation testing and production launch feedback.
📚 3. Lessons Learned #
Use this section to capture insights that can be reused in future DFMEAs or designs.
| Category | Lesson Learned | Impact |
|---|---|---|
| Mechanical Design | Add spline for all high-torque interference fits | Reused in Gen-4 pump |
| Sealing | FKM seal outperforms EPDM in coolant durability | Updated design standards |
| EMC | Ground stitching vias reduced emissions by 80% | Used in all PCB layouts |
✅ This can be added to your central LL database or knowledge base
🔗 4. Linkages to Other Quality Tools #
This step also ties the DFMEA to:
- DVP&R – Verifies if actions are validated
- Design Control Plan – Ensures critical risks are monitored in production
- Process FMEA (PFMEA) – Hand-off of risks from design to process
- Change Management (ECN/PLM) – Traceability if design changes
✅ These linkages should be documented for audit readiness
📦 5. DFMEA Report Package (for Release or Audit) #
What to Include:
| Document | Description |
|---|---|
| ✔️ DFMEA Excel or Software Export | Full 7-step output with ratings and actions |
| ✔️ Summary Table | One-pager overview |
| ✔️ Risk Acceptance Sheet | Residual risk justifications |
| ✔️ Lessons Learned Log | Future reuse items |
| ✔️ DVP&R or Validation Link | Connection to test plan |
| ✔️ Design Control Plan (if ready) | Critical characteristics |
| ✔️ Sign-Off Sheet | Cross-functional approval signatures |
📥 Provide a sample zipped package as course resource
✅ Outputs of Step 7 #
By completing Results Documentation, you will have:
- ✅ Summarized the DFMEA using a Summary Table
- ✅ Captured and justified residual risks
- ✅ Documented and shared lessons learned
- ✅ Linked DFMEA to other core tools (DVP&R, Control Plan, etc.)
- ✅ Prepared the DFMEA report package for review or release
🔗 Internal Linking Suggestions #
- Download: DFMEA Summary Table Template (Excel)
- Download: Residual Risk Statement Format (Word)
- Guide: How to Capture Lessons Learned in DFMEA
🧠 Pro Tip #
“DFMEA isn’t complete when the form is filled — it’s complete when the learnings are reused, actions are tracked, and decisions are visible.”
🏁 Conclusion #
Step 7 turns your DFMEA into a tool for decision-making — not just a form for compliance. With proper results documentation, you ensure:
- Audit readiness
- Team alignment
- Future cost avoidance
- Engineering knowledge transfer
This completes the full DFMEA 7-step process for our Electric Water Pump example.
