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Concept
Design review based on failure mode
Summary
Design review based on failure mode (DRBFM) is a tool originally developed by the Toyota Motor Corporation. This tool was developed based on the philosophy that design problems occur when changes are made to existing engineering designs that have already been proven successful.
DRBFM methodology was developed by Tatsuhiko Yoshimura, a Quality Expert and a professor at Japan's Kyushu University. Yoshimura knew that design problems occur when changes are made without the proper level of supporting documentation. Using the philosophy of preventative measures (Mizenboushi), he created his own philosophy of DRBFM. Dr. Tatsuhiko Yoshimura supported the development and usage of DRBFM at many companies. He believes companies that implement the usage of DRBFM will be a better company. He believes the implementation of DRBFM requires discipline and engagement of everyone to the one goal of adding value to the customer by meeting engineering functional requirements and customer expectations.
The philosophy of DRBFM centers on three concepts:
Good design
Good discussion
Good dissection
The DRBFM methodology is now a recognized documented process by SAE (Society of Automotive Engineers) and also by AIAG (Automotive Industry Action Group). SAE J2886 DRBFM Recommended Practice was published in 2013 and the AIAG DRBFM Reference Guide was published in September 2014. Bill Haughey is the chair of both the SAE and AIAG committees to ensure a consistent application of the DRBFM process within both documents.
The basis for reliability is not to change a design; therefore, Mr. Yoshimura believes that if a design changes, the change should occur in small increments. Disturbance to a design is caused by the discontinuity of implementing changes affecting the interfaces between parts and interactions between systems. The design should not be changed in two different places simultaneously, because making too many changes too fast has the potential to result in failures faster than our capacity to detect them. One key to successful change is to make changes visible.
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