Mapping function to failure mode during component development

When designing aerospace systems, it is essential to provide crucial failure information for failure prevention. Failure modes and effects types of analyses and prior engineering knowledge and experience are commonly used to determine the potential modes of failures a product might encounter during its lifetime. When new products are being considered and designed, this knowledge and information is expanded upon to help designers extrapolate based on their similarity with existing products and the potential design tradeoffs. In this work, we aim to enhance this process by providing design-aid tools which derive similarities between functionality and failure modes. Specifically, this paper presents the theoretical foundations of a matrix-based approach to derive similarities that exist between different failure modes, by mapping observed failure modes to the functionality of each component, and applies it to a simple design example. The function-failure mode method is proposed to design new products or redesign existing ones with solutions for functions that eliminate or reduce the potential of a failure mode.