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Training

Trust the Process

APQP Training Program

Advanced Product Quality Planning is the framework of procedures and techniques used to develop products. Test.

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DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and…

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DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design….

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PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the…

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PPAP Training Program

Production Part Approval Process is a standardized process in the automotive and aerospace industries that helps manufacturers and suppliers communicate…

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DFM/A Training Program

Design for Manufacturing and Assembly is a combination of two methodologies; Design for Manufacture, which means the design for ease…

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DMAIC Training Program

Lean Six Sigma – A structured and disciplined approach to making fact-based decisions that cover the DMAIC phases: Define; Measure;…

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DOE Training Program

Design of experiments (DOE) – provides a systematic method to determine the relationship between factors affecting a process and the…

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Reliability Engineering Training Program

Reliability Engineering describes a focused approach to complete Reliability Engineering methods and how they will benefit your organization

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ISO 26262 Training Program

Functional Safety describes how to implement a vehicle level functional safety program, create a HARA, and understand the interactions within…

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MSA Training Program

Measurement System Analysis is an experimental and mathematical method of determining how much the variation within the measurement process contributes…

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SPC Training Program

Statistical Process Control is a scientific visual method used to monitor, control and improve processes by eliminating special cause variation…

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FTA Training Program

Fault Tree Analysis is a systematic, deductive (top-down), graphical methodology for defining a single specific undesirable event and determining all…

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MFMEA / DFM M&T Training Program

Machine Failure Modes and Effects Analysis is a methodical approach for identifying all possible equipment failures in a manufacturing or…

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RCA Training Program

Root Cause Analysis – 8D is a methodical problem-solving process that covers the three common stages of correction: ⦁ Act…

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QSB Training Program

QSB will provide a summary of how to assess shop floor manufacturing systems. Training will include control of nonconforming products,…

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Poka-Yoke Training Program

Poka-yoke is a technique for avoiding simple human error in the workplace. Also known as mistake-proofing, goof-proofing, and fail-safe work…

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Process Awareness

Ability and knowledge to participate in  completing the FMEA Process

LEVEL 1

Competency

Ability and knowledge to lead a team in the FMEA Process

LEVEL 2

Proficient

Ability to teach and mentor Participants and Team Leads in the FMEA Process

LEVEL 3

Expert

Ability to lead an organization implementing FMEA

LEVEL 4

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DFM/A Training Program

Design for Manufacturing and Assembly is a combination of two methodologies; Design for Manufacture, which means the design for ease…

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PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the…

Learn More »

DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design….

Learn More »

DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and…

Learn More »

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PFMEA Training Program

Process Failure Modes and Effects Analysis is a step-by-step approach to identify and manage the risks of failures within the…

Learn More »

DRBFM Training Program

Design Review Based on Failure Modes is a focused approach of mitigating change risk within the product and process design….

Learn More »

DFMEA – FMECA Training Program

Design Failure Modes & Effects Analysis and Failure Modes, Effects & Criticality Analysis are a step-by-step approach to identify and…

Learn More »

Please visit ReliatrainGov.com for more information about Government Services

DRBFM Training Program

Design Review Based on Failure Modes (DRBFM)
Design Review Based on Test Results (DRBTR) (GF3 Methodology)

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COURSE DESCRIPTION

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.

COURSE OBJECTIVES

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

COURSE OUTLINE

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)
• Define Product (System, Subsystem, Component, etc.)
• Define Current Issues (e.g., Field, Test, Supplier Issues)
• Define DRBFM Plan - (Design Risk Level / Novelty)
• Define and Train the Team
• Define Usage Profile (e.g., Awareness Sheet)
• Define Product and Interfaces (Boundary Diagrams)
• Define Functions
• Define P-Diagram
• Define Current DVP (Design Verification Plan)
• Define known Guidelines and Best Practices
• Learn how the engineer and manager (DRBFM expert as needed) ensure preparation is complete and correct

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.
• Level of analysis is defined (system, subsystem, component)
• Functions and requirements assigned for each element of analysis (linked based on Preparation documentation)
• Failure modes, causes and effects defined for each element of analysis
• Assessment of Severity (Importance)
• Design Countermeasure defined for each cause (e.g., Guidelines, Best Practices, proven design or process)
• On-going proficiency assessment by DRBFM Expert

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
• Fault Tree Analysis Input
• Design for Manufacturing and Assembly Input
• Survivability analysis input
• Definition of Critical/Special Characteristics
• Process Integration (PFD, PFMEA, PCP, etc.)
• Design Actions
• Test (DVP) Actions
• Manufacturing Actions (Including Suppliers)
• Management Review and Approval to Proceed

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)
• Confirm Supplier Actions Results
• Confirm Process Integration
• Cross-functional Team and Management Review

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
• Results of DFMEA or FMECA and Audit feedback to organization
• Results of DFMEA or FMECA feedback to customers and suppliers
• Development or update of lessons learned, guidelines and best practices
• Celebrate with the team!

  • 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.

COURSE PREREQUISITES

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:

Commercial
Medical
Utilities
Aerospace
Consumer Lifestyle Products
Civil Engineering
Tooling and Equipment
Oil and Gas
Trains & Railroad Equipment
Military [DOD]
Government
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.