Learn how to proceed with DRBFM and how to effectively apply it to reliability design with exercises

What is DRBFM?

DRBFM stands for Design Review Based on Failure Modes.
This is a structured and systematic approach used in engineering to identify potential failure modes in a product or process and then develop strategies to prevent these failures.
It is an extension of the traditional Failure Mode and Effects Analysis (FMEA) but goes a step further by emphasizing detailed design review and discussion phases.

DRBFM was developed by Dr. Tatsuhiko Yoshimura at Toyota.
It focuses on encouraging participants to engage in open discussions regarding possible changes and their potential impacts.
The core philosophy is to emphasize prevention over correction, ensuring that design flaws are corrected early in the development process.

Why is DRBFM Important in Reliability Design?

In reliability design, ensuring that a product functions correctly over its intended lifespan is paramount.
DRBFM helps in achieving this by identifying possible weak points in a design before they can become catastrophic problems.
By meticulously exploring potential failure modes, you can enhance the product’s reliability significantly.

DRBFM emphasizes detailed consideration of even minor changes in design, material, or process.
This attention to detail helps in understanding the impacts of these changes thoroughly.
Understanding these impacts is crucial because small changes can sometimes have large and unforeseen consequences on product reliability.

Steps to Proceed with DRBFM

To effectively conduct a DRBFM, you need to follow a structured process.
This ensures that all potential failure modes are meticulously identified and addressed.

1. Planning

The first step in DRBFM is planning.
In this stage, you identify the scope of the review, including which parts of the design or process will be reviewed.
Defining the team members is also crucial, as it ensures that a variety of expertise is involved in the analysis.
Gather all relevant data and documentation, such as design specifications, past failure reports, and any modifications that have been made.

2. Execute the DRBFM Meeting

Organize a meeting where the involved team members can discuss the design in depth.
The objective here is to assess all aspects comprehensively.
Each member should be encouraged to ask why certain changes were made and to probe deeply to explore possible ramifications.
Facilitating a culture of open discussion aids in uncovering hidden concerns that may not have been initially apparent.

3. Identify Failure Modes

Once the team understands the design intricately, the next step is to identify potential failure modes.
The focus should be on changes, as these are typically where problems occur.
Make a list of all possible ways a change might lead to failure.
This list will form the foundation of the design evaluation process.

4. Analyze the Effects

For each identified failure mode, analyze the likely effects.
It is important to consider both direct and collateral effects.
Understanding how these failures could manifest in real-world scenarios is crucial for developing effective mitigation strategies.
Scenarios should be as comprehensive as possible, and the potential impacts on the end user should be a central focus.

5. Develop Mitigation Plans

Once you understand the potential failure effects, the next step is to create mitigation plans.
These plans typically involve design changes, process adjustments, or additional diagnostic tools that can help in early detection of the onset of a failure.
The goal here is not just to fix problems but to proactively prevent them.

6. Validate and Verify

After implementing mitigation strategies, the product or process design needs thorough validation and verification.
This involves testing the changes in a controlled environment and analyzing whether they effectively prevent the identified failure modes.
Validation ensures the intended reliability improvements are achieved.

Exercises to Apply DRBFM Effectively

Practical application of DRBFM helps in embedding the methodology within the team’s standard operating procedures.

Exercise 1: Case Study Review

Select a past project that used traditional FMEA and apply the DRBFM process to it.
Identify how DRBFM could have addressed failure modes more effectively.
This exercise helps in understanding the additional insights DRBFM provides.

Exercise 2: Real-Life Scenario

Pick a current or upcoming project and form a DRBFM team.
Follow all the steps outlined above from planning to validation.
This real-time application will help the team experience firsthand how DRBFM can improve reliability design.

Exercise 3: Role-playing

Conduct role-playing sessions where team members take on different roles in the DRBFM process, such as project manager, design engineer, and quality assurance tester.
This exercise helps each member understand the different perspectives and responsibilities within the DRBFM methodology.

Conclusion

DRBFM is a powerful tool that, when applied correctly, can significantly enhance the reliability of a product or process.
By systematically identifying and addressing potential failure modes early in the design phase, it ensures a higher level of confidence in the product’s performance.
Encouraging discussion and questioning within the team about even minor changes leads to robust designs and fewer in-field failures.
Implementing DRBFM involves commitment and practice, but the benefits in terms of reliability and performance make it an invaluable methodology for any engineering team.