NPI, DFM/DFA & Engineering Change worked example

Assembly Complexity Score with assembly failure severity rating of 15 score: a worked example in npi, dfm/dfa & engineering change

Push assembly failure severity rating up to 15 score and the picture changes. This example computes every intermediate figure at that operating point. Use it when assembly complexity in npi, dfm/dfa and engineering change needs a defensible ranking against other npi, dfm/dfa and engineering change risks for the next review.

The inputs for this scenario

  • Assembly failure severity rating: 15 score (raised for this scenario; the documented default is 6)
  • Assembly error occurrence likelihood: 4 score (unchanged)
  • Assembly error detection difficulty: 3 score (unchanged)

Working through the calculation

  • Applying the documented formula (Assembly complexity risk score = assembly complexity severity score × assembly complexity occurrence score × assembly complexity detection score) to the inputs above produces each figure below.
  • At this operating point the engine returns 8.15 score for assembly complexity risk score, the number this scenario is built around.
  • At this operating point the engine returns 15 score for assembly complexity severity score.
  • At this operating point the engine returns 4 score for assembly complexity occurrence score.
  • At this operating point the engine returns 3 score for assembly complexity detection score.

How this compares with the baseline

  • Against the tool's baseline example, where assembly failure severity rating sits at 6 score and the headline result is 4.55 score, this scenario comes in 79.12% above the baseline at 8.15 score.
  • It computes a single assembly-complexity risk number by multiplying severity, occurrence, and detection ratings for an assembly step or operation. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Assembly complexity risk score: 8.15 score (headline result)
  • Assembly complexity severity score: 15 score
  • Assembly complexity occurrence score: 4 score
  • Assembly complexity detection score: 3 score

Run it with your numbers

  • Every input above is editable in the live Assembly Complexity Score calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.