Design Review Based on Failure Mode (DRBFM) Course

Design Review Based on Failure
Mode
Dr. Rauf Tailony © Ben Tolon University
2020

Introduction
DRBFM: Design Review Based on Failure Mode
FMEA
Failure Mode and
Effects Analysis
DRBFM Dr. Tatsuhiko Yoshimura

Introduction
DRBFM == Preventive Maintenance
DRBFM== Capturing Change
Change = Opportunity/Challenge

Introduction
Change is a must to stay alive in the market!
If you don’t change; you will be changed

Introduction
DRBFM makes sure the change is delivered without loosing quality.

Objectives
 Understanding why we use DRBFM
 Knowing how to effectively implement
DRBFM
 Determine most beneficial techniques in
holding DRBFM practices

Outline
 Overview and Value of DRBFM
 Project Milestones & Requests
 DRBFM Approach
 Prep/Support Tools & Exercises
 DR Participant List
 Request to EDs; DRBFM Resources
 When & How Concern Appears
 Design Actions Taken to Prevent Concern
 How to Hold DRBFM Meetings; DR Guidelines
 Summary

DRBFM
 Why We do DRBFM?
Change is needed. Change creates Risk. We need processes to
identify and reduce Risks.
Risk in DRBFM- “The probability that a change point will trigger a negative outcome”
 Goal of DRBFM?
To produce a robust design.
Robustness - “Ability of a part to function as intended under unpredictable
environmental conditions or customer usage”
DRBFM is a mindset that is applicable to all stages of the Product
lifecycle.

DRBFM Structure
 [GD]3
Good design, Good discussion, Good design review(Dissection => Find
problems)
A collaborative approach towards the design process to identify problems and develop sustainable, robust
solutions.
For well designed systems; problems happen with changes (intentional and incidental)
[GD]3 Helps identifying these changes
Good design: Don't change a good/robust design/process
(fundamental principle of reliability).
…but, change is inevitable. Therefore,
have Good discussions: If changes must be made, involve others in
discovering potential problems. Collaborative dissection to find hidden
problems.
…by having
Good design reviews: Study the changes to identify and eliminate
potential failure modes.

DRBFM Structure
 MB
“Mizenboushi” is a mindset to proactively and predictively address
all direct and indirect potential aspects of a problem to prevent
failures == Proactive problem prevention

New Design = Good Design
DRBFM adopts the GD3 process to ensure that
“New Design” = “Good Design”

DRBFM Overview
 Structured method to identify critical discussion
points in preparation for Design Review (DR)
 Focus on “CHANGED POINTS” – Visualization
and analysis by critical thinking
 Active discussions and comparisons with similar
or previous models to detect as many potential
problems as possible
 OUTPUT: Robust design, improved illustration

DRBFM Benefits
 Manage risk from changes
 Promote robust design mindset by
leveraging experience
Robust = insensitive to variation
 PROACTIVE PREVENTION:
Predicting potential future problems
and resolving them before they occur.

Design Change Problem
 360 view ECU Module overheating
 Design change point

Design Change Problem
 Dimmer switch abrasion and melting
 Design change point

DRBFM Procedure Overview
Pre-work by
Design Engineer
•Visualize system
•Breakdown system hierarchy showing related parts
•Detail changes
•Define the "Functions“ or “Requirements”
•Identify "Concern points due to change"
•Dig deep to find true “Root Causes” (5-Why)
•Clarify the “Effect to Customer”
•Explain “Design steps taken to prevent concern”
Departments
Discussion
•Discuss "Are there other concerns?” and "Are there other considerations for
cause?"
•Discuss whether the concerns can be resolved through "Design
steps taken to prevent concern"
•Discuss and determine "Recommended actions"

DRBFM Worksheet
 Visualize
changes in both part
and part
environment
(surrounding parts,
usage conditions, etc.)
 Think carefully and deeply
about potential concerns
 Clarify concerns and
causes and prepare for
DRBFM
 Discuss the documents deeply with the
Experts and professionals

Milestones
 Level check sheet for DRBFM
 Purpose:
Measure quality of DRBFM
application including depth and
breadth of design information
6.0 total scale; 0.25 increments
Pre-DR by SE Release ≥2.5/4.0
(shaded portion)
Final by Genzu Release ≥4.0/6.0
 Certified DRBFM Expert role
– Guide the process to
achieve target
– Official level check score
reporting
– Submit to PDO for milestone
reporting

DRBFM Part selection
 100% of parts considered for DRBFM
• Tech Notice (target issue 1 month
after
project start)
• Sorting Sheet completed by ED/ES 1
week
prior to Z-led consensus meeting
• Consensus meeting w/ related
divisions
(target completion by K4 start)

DRBFM Approach
 Design engineer(s) think objectively
about changes and part function, to
identify and propose predictions for
potential concerns.
• Design engineer(s) obtain feedback
and advice from knowledgeable
experts, to ensure all other concerns
are identified and addressed.

Design Review Preparation
 Use DRBFM worksheet to visualize
assemblies and design parts with
related function of each part and
important properties.
• Clearly visualize the potential
problematic part or segment to the
DR members.

DRBFM Worksheet Goals
 System visualization.
 Capturing changed points.
 Problem Finding or prediction.

Worksheet Process
• Exploded views
• Hierarchy diagram
• Change list
Problem
Visualization
• Change point x Function Matrix
Problem
Finding
• 5 Why analysis
• Fishbone diagram
• Fault tree analysis
Problem
Solving
Change
Identification
Concern
Discovery
RootCauseAnalysis
Pre-DR

DRBFM Flow
1. Visualize
 Visualize the systems and related
details.
 Showcase old design (baseline) vs.
new design.
 More detailing for complex
assemblies.
 Include surrounding parts (system
subcomponents.
 Include direct and indirect changes.

DRBFM Flow
2. Hierarchy Diagram
System Assy
parts
Sub-Assy
parts
Individual
Parts
Reference
from
exploded
view
List of
compone
nts
Categor
y
changes

DRBFM Flow
3. Change List
System Assy
parts
Sub-Assy
parts
Individua
l Parts
Reference
from
exploded
view
List of
compo
nents
Categ
ory
changes Baseline New

DRBFM Flow
4. Function List
System Assy
parts
Sub-Assy
parts
Individual
Parts
Reference
from
exploded
view
List of
compon
ents
Function Addition
al
Function
s

DRBFM Flow
4. Function List
 List functions at system’s level and
then at part’s level.
 Include design characteristics when
possible.
 Consider system and parts at all
phases of product life.
 Apply Functions diagram to
organize concerns based on changes
in the Change matrix .

DRBFM Flow
4. Function List
 Notes:
 Understand the functions to identify
potential failures.
 Define the function and purpose of
each component in the system.
 Include the part interaction with the
surrounding parts.

DRBFM Flow
5. Change Matrix
List of
compone
nts
Catego
ry
Baseline New List of
Functions
F1 F2 F3
C1 --- --- --- O A# X
C2 --- --- --- X O A
#
C3 --- --- --- A
#
O X
C4 --- --- --- O X O
C5 --- --- --- A
#
X O
ChangeMatrix

DRBFM Flow
5. Change Matrix
 Concern discovery:
 Find the potential failure mode by studying the
interaction between the change points and the
functions list.

DRBFM Flow
5. Change Matrix
 Potential Concern Example:

DRBFM Flow
5. Change Matrix
 Potential Concern Discovery:
 Interactions should be carefully
considered for both past problems and those
previously unseen.
 Include a note of the conditions,
phenomena, timing of the event for future
reference (root cause).
 Seek input from experienced members.

DRBFM Flow
6. DR Members List
Participan
ts
8/5/2019 8/15/2019 8/20/2019 8/21/2019
Category
Company
Name /
Department
Participa
nt Name
Title
Invited
(O:
YES)
Attende
d
(O:
YES)
Invited
(O: YES)
Attended
(O: YES)
Invited
(O: YES)
Attende
d
(O:
YES)
Invited
(O: YES)
Attended
(O: YES)
Own
Departme
nt O O O O O O O O
Function/
Part
SHUSA
Area
AE/TA
Supplier
O O O O O O O O
Responsi
ble
Expert
Related
Design
Engineeri
ng Dept.
Testing
Dept.
Materials
Engineeri
ng

DRBFM Flow
6. DR Members List
 Preparation for Design Review:
 Visualize potential concerns identified by the
change matrix.
 Create A-Rank list and 5why (root cause
analysis) of each concern.
 Discuss with the DR experts the possible ways
to resolve/avoid the concerns.
1
• Problem Visualization
• Clarification of changes.
2
• Problem Finding
• Discovery of all potential issues.
3
• Problem Solving
• Systematic elimination of issues.

DRBFM Flow
7. A-Rank Worksheet
Part
Name/
Change
Point
Requiremen
t/ Function
Concern
(Failure
Mode)
When & How
concern
appeared
(Root Cause)
Effect
on
Custom
er
Design Actions
Taken to Avoid the
Concern
Recommend
ed Actions

DRBFM Flow
8. [5 Why] Worksheet

Proactive Problem Prevention
Systematic Approach
1. Visualize Changes.
2. Think deeply about potential concerns.
3. Clarify concerns and causes.
4. Discuss concerns with experts.
5. Reflect preventive measures on design
and manufacturing.

Building A Design Story
1. Identifying changes.
2. Identifying general functions.
3. Identifying relationships and general
concerns.
4. Arranging the changes.
5. Detailing the functions.
6. Developing problem(s) statement(s).

Identifying Changes
1
2
3
4
Visualize parts
and
surroundings
Breakdown
assemblies and
sub-assemblies
Detail changes
Compare “Old”
vs. “New”
models

Arranging Change
1. Group items in “change comparison
list” column by system, assembly,
component.
2. Include an advanced level of details.
3. Include the reason behind the change
(Why we wanted to move from “Old”
to “New”.
4. Follow top down approach in detailing
(e.g. Assembly, sub-assembly, part,
components)

Identifying Functions
1. Identify basic purpose of each system,
assembly, component.
2. Identify all other functions considering
entire part life (all customers).
3. Identify function at interface with
surrounding parts.
4. Generalize (capture the big picture)

Detailing Functions
1. List the details of generalized
descriptions.
2. Add measurable parameters for
evaluation.
3. List criteria components (e.g. items to
measure, record, inspect)

Identifying Relationships
1. Every interaction should be carefully
considered for both past problems and
those previously unseen.
2. Include a note of the conditions,
phenomena, timing of the event for
future reference (root cause analysis).
3. Seek input from experienced
members.

Writing A Problem Statement
Concern
Problem statement
requires
Failure phenomenon
e.g. Fuel Tank wall
cracks at corner “x”
at high speeds
Fuel tank welding
line separates
At high temperatures
Failure Defined
When
How
Where

What is Root Cause Analysis?
1. Tracing the problem all the way to the
source.
2. Described by the depth where an
intervention could be implemented to
prevent the outcome (recurrence
prevention).
3. DRBFM Application → Potential causes
considering Robust Design.

Root Cause in DRBFM
 Problem Statement
 Failure phenomenon
 For parts and components
 When in part life
 Where (area of failure on part)
 Causes “Root Cause”
 Defining how by asking why
 Possible conditions and circumstances
 Different perspective and assumptions
 Environment impact on design and
manufacturing

Root Cause in DRBFM
Car is Overheating
Engine Temperature increased
Poor engine cooling
Fans are not working
Power supply cable is disconnected

Steps to Avoid Concerns
Root Cause Steps to avoid concern
Undefined tolerance Define tolerance
Low material stiffness Increase material stiffness
Unclear position Define position clearly (x, y, z)

Potential Causes
Main types of causes:
1. Control
 Parameters with adjustable nominal values.
 Design parameters
 Process variables
2. Noise
 Sources of variability (internal and external to the
systems)
 Environment
 Customer use
 Process variations

Root Causes Tips
1. Use simple and direct description.
2. Ensure simplicity and clarity through
detailed explanation.
3. Locate controlled factors versus
uncontrolled factors.
4. Identify potential causes from various
perspectives.

Root Causes Tips
 Address each root cause with Design evidence/
engineering studies:
• Design check sheets.
• Benchmarking results.
• Hand calculations with predicted safety margins.
 Link each identified cause (control).
 Show completed items (not future plans).
 Be quantitative to clearly satisfy function and requirement.
 Cautious use of CAE by including inputs, assumptions,
boundary conditions and results.

DRBFM Process Summary
Change
Visualizing
Old vs. New Design
Change Comparison
List
Hierarchy Diagram
Change Matrix
DR Participants
List
‘A’ Rank Worksheet
Root Cause Analysis
[5 Why]
DR Meeting(s)
DRBFM Scoring Sheet
Durable Product
Functions List

DRBFM Worksheet
DRBFM Worksheet Template

Mechanical DRBFM Example
 Mechanical DRBFM Worksheet
 Product:
VS.

Electrical DRBFM Example
 Electrical DRBFM Worksheet
 Product:
VS.

Software DRBFM Example
 Product:
VS.

System DRBFM Example
 Product:
VS.

Typical Failure Modes
|Electrical

Typical Failure Modes
|Software

Design Review Based on Failure Mode (DRBFM) Course

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (20)

Similaire à Design Review Based on Failure Mode (DRBFM) Course

Similaire à Design Review Based on Failure Mode (DRBFM) Course (20)

Plus de Ra'uf Tailony

Plus de Ra'uf Tailony (18)

Dernier

Dernier (20)

Design Review Based on Failure Mode (DRBFM) Course