Ability and knowledge to participate in completing the FMEA Process
Ability and knowledge to lead a team in the FMEA Process
Ability to teach and mentor Participants and Team Leads in the FMEA Process
Ability to lead an organization implementing FMEA
DRBFM Training Program
Design Review Based on Failure Modes (DRBFM)
Design Review Based on Test Results (DRBTR) (GF3 Methodology)
This course will provide management and engineers an introduction to the Toyota GD3 methodology and company culture. Design Review Based on Failure Modes (DRBFM) is a methodology focused on change management and continuous improvement. The course comprehends the industry best practices and organizes them into a disciplined and logical DRBFM Process – PLUS bonus examples of DRBFM analysis and preparation documents are provided!
The foundation of this training material comes from Bill Haughey’s book “Design Review Based on Failure Modes & Design Review Based on Test Results Process Guidebook”, the SAE J2886 DRBFM Recommended Practice, and AIAG DRBFM Reference Guide. The DRBFM methodology is an interactive systems engineering process consisting of 5 steps: 1) Planning and Preparation, 2) Problem Analysis of Design Risk – Forum One, 3) Interaction with Design Reviews and Experts, 4) Actions Results, and 5) Audit, Feedback, and Follow-up Loop. This course defines how each process step supports engineering decisions and the development of robust product and process designs.
This training program is intended to provide an introduction and foundation of the Design Review Based on Failure Modes (DRBFM) and Design Review Based on Test Results (DRBTR) based on defined industry standards and requirements. This training will provide foundation knowledge of the GD3 culture and mindset. Mastering the content will improve product quality, reliability, durability, and launch effectiveness. At the end of this course you should be able to:
• Define when and why DRBFM is required during the Planning phase
• Define the relationship of DRBFM and DFMEA
• List Preparation documentation necessary to complete DRBFM
• Describe how functions and requirements are inputs within DRBFM
• Describe the relationship between a failure mode, effects of failure, and causes
• Define the difference between DRBFMcountermeasures and DFMEA controls
• Define the Risk Calculation process for DRBFM
• Define the difference between DRBFM and DFMEA Risk Calculation
• Describe how to Reduce and Manage Risk, and when actions are necessary
• Define the difference between DFMEA and DRBFM actions
• Define the relationship between DRBFM and PFMEA
• Define the roles of both management and engineers within the DRBFM Process
• Define the importance of the Audit, Feedback, and Follow-up information to the DRBFM team and organization
• Define how DRBFM fits as a change management tool
• Define the relationship between DRBFM and DRBTR
• Define the difference between a DRBTR observation and a test issue
• Use DRBFM as a tool in an engineer’s daily activity
The course eliminates bottlenecks and process inefficiencies by comprehending industry best practices and organizes them into a disciplined and logical 5 Step DRBFM Process which includes:
• Planning and Preparation
• Problem Analysis of Design Risk
• Technical Reviews
• Actions Results
• Audit, Feedback, and Follow-up Loop
|Step One: Planning and Preparation||
The planning phase supports the definition of the product content (systems, subsystems, and components) that requires analysis. Participants will receive example criteria and modifiable templates they can use to evaluate any product to determine the DRBFM scope and cross-functional team. The following are elements of Step One:
• Define the “Voice of the Customer” (Requirements)
|Step Two: Change Point Analysis (Assessment of the Design during Development)||
The assessment phase provides a step-by-step process for the relevant engineer to complete assessment of their design. The training material provides modifiable templates and examples they can use to complete the DRBFM. The following are elements of Step Two:
• When done correctly, the preparation information will provide the DRBFM outline for the engineer to complete the required reliability risk analysis.
|Step Three: Team Assessment and Actions||
The engineer leads the team through technical reviews that includes assessment of their design. Various technical reviews require different experts that can uncover hidden design deficiencies. The linkage and collaboration with the interfacing processes will yield a robust design. The following are elements of Step Three:
• Design Reviews Input
|Step Four: Actions Results||
DRBFM has little value unless the recommended actions are fully executed and decisions are made based on actions results and reassessment of risk. The following are elements of Step Four:
• Actions Results Closure (Design, Test, & Manufacturing)
|Step Five: Audit, Feedback, and Follow-up Loop||
It is recommended the responsible engineer (or team) or a third-party complete an audit of the DRBFM. The results of the DRBFM and the audit should be shared with the organization and the customer or appropriate suppliers. The following are elements of Step Five:
• Audit of the DFMEA or FMECA and Process
- Design Review Based on Test Results (DRBTR) - Bonus Training Section
GD3 defines DRBTR as a specific process to identify buds of problems that might lead to a negative customer experience. This step requires the team to think in terms of finding “Observations” and not only issues.
This course also provides foundation knowledge of Design Review Based on Test Results (DRBTR) training based on Tatsuhiko Yoshimura’s training and vision. A detailed process and template is provided to enable organizations to implement the best practices of DRBTR.
- COURSE OUTLINE of DRBTR Section
The course eliminates bottlenecks and process inefficiencies by comprehending industry best practices and organizes them into a disciplined and logical 5 Step DRBTR Process which includes:
• Planning and Preparation
• Phase One Analysis
• Phase Two Expert Team Analysis
• Observation Resolution
• The audit, Feedback, and Follow-up Loop
The 5 steps of this training module will provide foundation knowledge to complete the DRBTR process. The DRBTR templates are provided to document the results of each project. Participants will understand the difference between an observation and a product issue.
Throughout the training, the participant will be required to take various quizzes that test proficiency. At the end of the training, the participant will also be required to complete a course survey based on the course material and the instructor. ReliaTrain uses the results of the quizzes and surveys to update the training to provide the best experience to participants.
This is a Level One foundation training module and does not have required prerequisite training or experience. However, this course is a Prerequisite for higher level (Competency, Proficient, and Expert) DRBFM and FMEA Certification.
COURSE RECOMMENDED PARTICIPANTS
DRBFM training supports the roles of Product Design Engineers, Safety Engineers, Reliability Engineers, Software Engineers, Materials and Fasteners Engineers, Maintenance / Service Engineers, Test Engineers, Manufacturing Engineers, Quality Engineers, Supplier Quality, Chief Engineers, DRBFM Leads, Logistics, Management, and Aftermarket Engineering [Including Suppliers].
This DRBFM training program is intended for all industries including but not limited to:
Consumer Lifestyle Products
Tooling and Equipment
Oil and Gas
Trains & Railroad Equipment
Phones & Personal Devices
The output of this course meets the objectives of product development processes (e.g., SAE Reliability Handbook HB0009), and DRBFM standards (e.g., SAE J2886 DRBFM Recommended Practice, AIAG DRBFM Reference Guide, and linkage with AS13004 PFMEA and Control Plan Standard).
ReliaTrain training modules are designed to meet industry standards and can be modified to meet company specific requirements. This course is offered Online to enable participants to take the training at their own pace and it is available 24/7 over a one-year period. Upon successful completion of this course the participant will receive a “Certificate of Completion” and also 0.9 CEU’s towards their professional certification.