1. How to put DRBFM to good use
GUIDANCE FOR INTRODUCTION OF DRBFM
October 10, 2002
Prepared by: KYOHOKAI Preventive Measures W/G
General editor: TMC MB Promotion Office

2. The initial defects only have remained.
■ WHY MIZEN BOUSHI NOW?
In the past, the defective fraction used to be tend to gradually decline.
As a result of taking the measures to accelerate the reoccurrence pre- ventive action for initial defects,
Month of production
The initial defects only have remained.
From now on, the initial defects need to be prevented by taking the Preventive measures.
Month of production

3. ■ TENDENCY OF DESIGN DEFECTS
 The reoccurrence of design defects was decreased by various types of measures.
→ Reflection of past troubles
→ Design standardization
Reoccurrence
10%
Points of change
50%
 Current design defects concentrate to:
・ Newly designed portions,
・ Modified portions, and
・ Portions which have been forced to be changed!!
New occurrence
40%
The initial design defects cannot be decreased unless the preventive measures are not positively taken!!

4. Design ■ ENVIRONMENT SURROUNDING DESIGNING
Short-duration development
Cost reduction
New mechanism and new components
Reduction of claim costs
Design
Cannot help changing despite desiring not to change. Have no time left despite desiring to verify more fully.
Find out points of concern earlier, completely resolve all issues, and reflect the results to drawings.
→ Early enhancement of the completion of drawings.

5. DRBFM＝Design Review Based on Failure Mode
■ DRBFM FOR MIZEN BOUSHI
DRBFM＝Design Review Based on Failure Mode
 Narrow down FMEA further, turn the attention to the new points and changed points, and clarify the point of concern there. “How the designer convey his point of concern to the following process?”
→ Have made the verification like this because the modified part was such and such and the concern was such and such. But, a failure mode like this cannot be prevented within the area of my function.
 Narrow down the theme of DR and implement DR.
“Based on the result of the designer’s FMEA, the persons concerned and specialists in various fields should make a discussion to perceive the points of problem and determine the solution.”
→ I have taken preventive measures up to this point. But, isn’t there anything else that I must do now?
→ “What did the designer do in his design study (concrete study to eliminate the point of concern)?” Persons concerned must verify and thoroughly and firmly discuss this point.
（※FMEA = Failure Mode & Effects Analysis
= Analysis of failure mode and degree of its incidence.）
It is initially necessary to make it a rule to utilize the “DRBFM worksheet” with as ease as in writing a minute.

6. ■ DEPLOYMENT OF DRBFM AND ITS EFFECTS
DRBFM at design ↓ Warranty at design and evaluation stages (DRBFM with many divisions) ↓ Extraction of significant properties ↓ DRBFM of process ↓ Decision of the method of process warranty and diagnosis of the degree of warranty ↓ Reflection onto QCMS (QA network) Since DRBFM is the basic factor which makes the job flow, it becomes a greater system leading to design and to mass production.

7. ■ EXAMPLES OF DRBFM SHEET AND ENTRY
DRBFM Sheet (for new design and design change)
Theme (roughly identified region)
Points of change (portion which was modified and portion which changed)
Model :
System : (Common name of Project)
Component :
Prepared by : (Name of designer)
Design Review Based on Failure Mode
DR member
Name of component and point of change
- to be described for each component as far as possible
Function
(concretely)
Point of concern related to change (failure mode)
In what occasion does the point of concern occur?
Impact on customers
RPN
What design was made to eliminate the point of concern?
This should include items to be complied with in designing, design standard, items to be checked, etc.
Loss of function and lack of marketability caused by the change
Isn’t there any other point of concern?
(DRBFM)
Cause / factor (state concretely and numerically)
Isn’t there any other factor to be considered?
(DRBFM) Ａ Ａ Ａ Ａ Ａ
Significance
Difficulty to detect
0SD
Frequency of occurrence Ａ
NO.:
Prepared on:
Amended on: Ａ
will be entered at the time of designing and the rest will be entered after DR.
Recommended responses (result of DR)
Activities implemented as a result of the response
Steps
Person in charge
Deadline
Person in charge
Deadline
Items to be reflected onto designing which were indicated in DRBFM
Items to be reflected onto evaluation which were indicated in DRBFM
Items to be reflected onto production process which were indicated in DRBFM
Person in charge 1 2
Deadline

8. ■ HOW TO PROCEED DRBFM - 1 (First half of DRBFM - FMEA stage)
1. Have DRBFM worksheet at hand when prepare drawing (or specification).
2. Check the drawing and enter the following items in the worksheet: • Name of new component (or name of modified region) • Function of the component (region) • Point of concern related to the change
3. Enter the points of concern being considered in the box “In what occasion does a point of concern occur?: Cause / factor”. (Make the best of FMEA Support System, Extraction Matrix, and others.)
4. Enter “Impact on customers” and evaluate its significance on a scale of one to ten.
5. Enter measure of design and design logic in the box concretely into “What design was made to eliminate the point of concern”. (Think out fully and firmly since this is the most important part.)
6. Distribute the completed DRBFM to the person in charge of DR of each division and other people concerned (together with drawing and reference documents).
Special notes (points to be attended in entering):
• Avoid abstract expressions such as “bend” or “deformation”, but use numeric.
• Avoid expression “defective”, but express “By what and how the defect was caused, and what symptom is produced”.
• Don’t mind appearance. Handwritings or memos can be used as basis.
• Don’t make anything not understandable to the other persons’ eyes. Use expressions understandable to everybody.

9. ■ HOW TO PROCEED DRBFM - 2 (Latter half of DRBFM - Design Review)
1. Participating members
• Chairman: A person who can carry forward the meeting neutrally, elected by the joint team (Project) members
• Presenter: The person in charge of design who prepared DRBFM worksheet
• Clerk: A person related to designing to record opinions given in DRBFM discussion
• Discussion members: Persons related to design, evaluation and technical specialists (Production Technology, Quality Control and Manufacture may be requested to participate in accordance with its contents.)
2. Materials to be prepared
• DRBFM worksheet (which was prepared by the person in charge of designing)
• Drawing (One which shows the details, such as part drawing, is preferable)
• Actual product (Cut product is desirable as far as possible)
• White board and Post-it (to record the contents of discussion and opinions given)
3. How to carry forward the meeting
 The designer explains the details of design contents (points of change and their peripheral matters).
‚ The designer presents FMEA considered for each theme (points of change and points of concern in designing).
ƒ Discuss each theme in light of drawing and actual product (plus work-site).
„ Other DRBFM members positively give their opinions on “whether there are other points of concern and other factors to be considered”.
… The clerk writes opinions given in the discussion on Post-it.
† Finally, each member gives his opinion as to “recommended responses”.
‡ Fill out the item of “Recommended responses” and finish one theme .

10. ■ TIMING FOR THE IMPLEMENTATION OF DRBFM
■ Design DRBFM
[Initial Meeting]･･･ (This can be omitted depending on time and occasion)
 Implement DRBFM at the stage of framing, based upon specification, framing chart, product in the past, and so on. Also implement FTA if necessary.
‚ Based on the contents of the above, the implement DR by persons concerned.
[Second Meeting]･･･ (Implement this without fail)
ƒ Implement thorough DRBFM based upon prototype drawing.
[Third Meeting]･･･ (Implement this without fail)
„ Implement based upon tested product.
 However, the number of meetings maybe adjusted on a play-by-ear basis. 
■ Process DRBFM
 After the third Design DRBFM, implement the first DRBFM for 1A.
‚ After the 1A production has been completed, implement the second DRBFM.
If no issues are left after the second DRBFM, it will be finished. Deploy into QCMS.
(Note: Firmly pin down the difference between the prototype (process) and mass production (process).
■ Implement DRBFM when a point of modification (change) has occurred.

11. ■ THEME OF DRBFM IMPLEMENTATION (Case example)
1. When operational mechanism or structure was newly designed or modified,
2. Newly design a new IC and design a peripheral circuit of the IC.
3. Consider the change in physical relationship among the parts and so on.
4. Consider the change in the portion around a sliding part such as button.
5. When a I/F between a software and another software has been modified (plus connection or link between software and hardware).
6. When a new material or material which changed is used.
7. When a new process or process change is necessary.
8. When another company’s related component has changed.

12. ■ DEPLOYMENT PLAN & HOW TO CARRY FORWARD (Example)
(Example) Annual plan
Mar
Apr
May
June
July
Aug
Sept
Oct
Nov
Dec
Jan
Feb
Mar
Elect promoting members of each division.
Peruse and comprehend the guidebook in each division.
Hold a lecture meeting for promoting members.
1st Meeting
2nd Meeting
Select object model of each division.
Implement DRBFM for each object model and scrutiny its contents.
Verify the progress and follow up the result. ○
Verify the contents of the implementation.
Repeat the implementation and continue the improvement.
Wrap up the year’s activities. ○
(＊ The above is an example where the introduction duration is set to be one year.)
 Elect promoting members from each division.
‚ Each promoting member peruses “Abecedary” and “Guidebook” (self-study): Use “Guidebook for GD³ Activity”.
ƒ Lecture meeting for promoting members
• 1st Meeting = Briefing outline (A person who received Toyota’s lecture shall be lecturer)
• 2nd Meeting = Case study (It is important that members actually practice for themselves.)
„ Each promoting member deploys the measures in his division (The concept is explained using “Abecedary” to all members at the First Meeting.)
… Select a model in each member’s division. (Implement a test in each division.)
† Period of implementation by promoting members
‡ Advisor (who received Toyota’s lecture) and promoting members scrutiny the contents.
ˆ Review the method of deployment and continue improvement. → Full-scale implementation

13. ⇔ ■ KEY POINTS / HEART OF DRBFM Discuss. Think. are important.
1. Fully dig out the change points, points of concern and causes.
2. Important points in carrying forward the activities are:
Thorough and firm discussion  Stimulate the ability of perception of each other  Perception by everybody
3. The points to be attended are:
 Don’t be uniform. (Just filling out the form is NG.)
‚ Make an open-minded discussion.
ƒ Look at object closely and think out by yourself. (Design theory is important.)
„ Respect the opinions of specialists. ⇔
Discuss.
Think.
are important.
• Reoccurrence prevention  can be done by checking past troubles
• Preventive measure  cannot be found without thinking = Implement DRBFM

14. REFERENCES (7 pages)
1. Procedure of introduction of DRBFM to company (Example)
　　　　　　　　　　　P1
2. DRBFM Glossary
　　　　　　　　　　　P2, P3, P4
3. Extraction Matrix for changed points, modification points and concerned points in DRBFM
　　　　　　　　　　　P5, P6, P7

15. P1

16. P2 DRBFM Glossary (1/3) No. Term Explication Remarks 1 GD³ Activity 2
• Good Design,
• Good Discussion, and
• Good Design Review
are considered three factors for forestalling the occurrence of problems by “going back to the basics”, and called GD³. 2
ＤＲＢＦＭ
Stands for Design Review Based on Failure Mode. It is a method to combine FMEA for creation and design review. This method aims to lead to the Preventive measures against problems by focusing attention on points of modification, strengthening the creativity and discussing points of problem, and thereby stimulating the brains of each other and perceiving various matters. 3
Creative FMEA
Considering that to perceive various matters while strengthening the creativity to lead it to the Preventive measure, it means the tool for getting idea in this process and to “pitch and catch” opinions. 4
Point of modification
In DRBFM, we first clarify the point of problem, i.e. pay attention to the portion which was modified and consider the point of problem in order to effectively carry forward FMEA. In that case, we make verification on the portion which has changed (e.g. rise of temperature of surrounding area, change in form, material, oil/fat, etc. of the counterpart).

17. P3 DRBFM Glossary (2/3) 5 Point of change 6 DRBMF worksheet 7
In DRBFM, we focus attention on the point of amendment and consider in what environment the object part is used from the viewpoint of customers, before we consider what problem are apprehended.
In other words, we can clarify the point of concern related to disorder in the function of the part and lack of marketability by deliberating the change in the stress (environmental conditions for use) of the object part. Thus, the portion which has changed along with the change in the environmental conditions of use or similar is called point of change. 6
DRBMF worksheet
Worksheet which is used for DRBFM.
Its basic composition comprises the part of FMEA which is implemented by focusing attention on the point of modification and point of change, and the part of DR which discusses recommended responses (design, evaluation and process) against the point of concern extracted by FMEA and the cause or factor of its occurrence, for each of which the contents of the implementation are to be entered. 7
Point of concern and its cause
Point of concern (failure mode) which comes out of considering the environmental conditions to be used, by making modification.
We must concretely state “Which region produce what sort of defect” in relation with the point of modification and point of change, and not in such generally-used words as “defect in ....”. DRBFM enables what is difficult to be listed up without omission within a short time by one person to be connected to a new idea by a discussion among a number of participants over it from various viewpoints. As for its cause, we must concretely point out what (the region of) it is. Half-baked cause is NG. 8
Item to be reflected onto the designing
This means a designing means for the purpose of resolving the cause or factor of occurrence of the point of concern.
In this case, we must concretely and clearly state as “The .... region has secured R0.5”, and not “based upon the design standard” or similar.

18. P4 Explication of Terms in DRBFM (3/3) 9
Item to be reflected onto the evaluation
This evaluates the adequacy of the designing response to resolve the cause or factor of occurrence of the point of concern.
In this case, we must clearly and concretely state as “The measuring of the dimension of the sliding part has been implemented after the operational endurance test”, and not “Various sort of endurance test has been implemented” or similar. 10
Item to be reflected onto the manufacturing process
In case there is a factor related to the manufacturing process, the items onto which it is to be reflected (building method, part processing method, their manufacturing conditions, etc.) must be clarified in order to resolve the cause or factor of the point of concern.
Its result should be reflected onto the QC process list as concrete items.
It is recommended that the items to be reflected onto the manufacturing process undergo process DRBFM separately. 11
Items to be reflected onto the process design
Identify the items related to the process design out of those to be reflected onto the manufacturing process and implement and reflect them. To be concrete, clarify the facilities, method of process, method of work, manufacturing conditions, etc. 12
Item to be reflected onto the process control
Identify the items related to the process control out of those to be reflected onto the manufacturing process and implement and reflect them. To be concrete, clarify the facilities check-up, facilities maintenance, manufacturing conditions, etc. 13
FMEA Support System
The support system developed by Toyota, which enables to implement high-level FMEA dialogically between a designer and a PC in a short time. 14
Extraction Matrix
(Perception Sheet)
The “idea-supporting sheet” which facilitates to easily carry forward DRBFM by listing up common languages in order to enable everybody to perceive the point of modification and its point of concern at a certain level.

19. Explanation of Extraction Matrix (DRBFM Perception Sheet)
1. Purpose
Extraction Matrix is a chart which is set to facilitate to easily carry forward DRBFM by listing up common languages in order to enable everybody to perceive the point of modification and its point of concern at a certain level.
2. How to use it
(1) Object key words
• A phrase which expresses what the point of modification and point of change will be.
• Key words will be changed according to the object product. Also, they need to be broken down into more concrete contents if necessary.
(2) Key words to extract the point of change and point of modification
• Phrase which expresses the point of modification or point of change made more concrete and easier-to-understand.
(3) How to use the matrix of the object and point of modification
• When the intersection point of the object, point of change and point of modification has been extracted, think up concrete content regarding that part and enter it in the point of modification in DRBFM worksheet.
(4) Key word of impact affecting the point of change and point of modification
• Phrase of stress imposed upon the point of change and point of modification
• The key word will be changed according to the object product. Also, they need to be broken down into more concrete contents, if necessary.
(5) When the phrase of impact affecting the point of change and point of modification has been extracted, think up concrete content with regard to that part.
(6) Key word to extract the point of concern
• Phrase which expresses the point of problem estimated to occur as a result of the stress imposed upon the point of change and point of modification.
• The key word may be necessary to be changed according to the object product. Also, they may be necessary to be broken down into more concrete contents depending on the case.
(7) When the phrase of the point of concern has been extracted, think up concrete content with regard to that part and enter it in the point of concern in the worksheet.

20. P6 DRBFM Extraction Matrix
■ Perception Sheet (Point of change, Point of modification, Point of concern) 1/2 P6

21. P7 DRBFM Extraction Matrix
■ Perception Sheet (Point of change, Point of modification, Point of concern) 2/2 P7