ADAPTING QUALITY PLANNING TOOLS TO EVOLVING PRODUCTS AND MANUFACTURING PROCESSES: THE CASE OF FMEA

Łukasz Rudolf; Marek Roszak

doi:10.17222/mit.2026.1661

Łukasz Rudolf School of Doctors, Silesian University of Technology, Faculty of Mechanical Engineering, Department of Engineering Materials and Biomaterials, Stanislawa Konarskiego 18A St., 44-100 Gliwice, Poland
Marek Roszak Silesian University of Technology, Faculty of Mechanical Engineering, Department of Engineering Materials and Biomaterials, Stanislawa Konarskiego 18A St., 44-100 Gliwice, Poland

DOI: https://doi.org/10.17222/mit.2026.1661

Keywords: FMEA, PDCA, quality planning tools, Industry 4.0 in quality management

Abstract

This study examines the evolution of design failure mode and effects analysis (DFMEA) in response to the automotive product transformation from conventional to mechatronic systems. The research combines a literature review with case studies to identify key changes in risk assessment methodology. The analysis compares severity ratings between conventional and mechatronic systems, with reference to the corresponding process failure mode and effects analysis (PFMEA) changes. Results indicate systematic increases in the severity of failure modes in the mechatronic DFMEA and decreasing differences between DFMEA and PFMEA risk assessments, reflecting the blurring of the boundaries between design and process risks. The study confirms the need for a more systemic risk analysis that considers complex component interactions and the increased impact of the production process on modern mechatronic product functionality.

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