Reliability Problem Prevention Method for Automotive Components - Development of GD ³ Activity and DRBFM (Design Review Based on Failure Mode)- 2003-01-2877

Recently, the concept of Mizen Boushi (reliability problem prevention) has been applied in automotive development as a tool to refine drawings to the greatest completion possible by the prototype stage. GD³ is a quality innovation process that supports this objective, based on the pillars of Good Design, Good Discussion, and Good Design Review. Good Design tries to nip problems in the bud, and Good Discussion and Good Design Review are used to formulate the best countermeasures to those problems.

The process utilizes creative FMEA (Failure Mode & Effects Analysis), FTA (Fault Tree Analysis), and a System Design Review. These tools focus attention on the many potential problems that could occur due to a change in design or environment. The System Design Review is especially useful to examine potential failure modes, root causes, part drawings, and prototype part designs. This is followed by a Design Review Based on Failure Mode (DRBFM for short), as a tool to guide discussion. In this way, it is possible to generate the best approach to handling design, evaluation, and production concerns. This paper will introduce some of the specific ways that this creative process is currently used in development as a tool to prevent problems.