Linking design reviews with FMEA to quickly mitigate the risk of change…design review based on failure modes
Bill Haughey · 2017
Design Review Based on Failure Modes (DRBFM) is a deep analysis process that focuses on engineering changes once a baseline design has been established. A key component of the DRBFM process is the emphasis on development of an organizational culture that is focused on meeting functional requirements and customer expectations. Supporting the engineer, both within and at all levels of the supply chain, is the foundation of the DRBFM methodology. DRBFM is an analytical process used to address design and process changes throughout the product development process, including running changes at launch and postproduction (up to product retirement). The basis of the process is the frontloading of the engineering efforts to 978-1-5090-5284-4/17/$31.00 ©2017 IEEE clearly define the impact of change and eliminate the need for extended engineering activity due to decoupled and sequential processes. The DRBFM process is inclusive of all systems engineering activities that impact quality/reliability/durability (QRD), service, cost and delivery. The process links the analysis of the impacts to design, validation, service, and manufacturing (including suppliers). Since DRBFM is focused on change, the process fits either directly into the product development cycle, or within the change management process. Most manufacturers have well-defined systems engineering product development processes. DRBFM can add value to the product development process. There are multiple opportunities during the design cycle where DRBFM can be an essential tool and create a culture of focus and efficiency in product development processes, especially in the following scenarios: creation of a new design; use of a similar design for a new application; the modification of a current design; and changes to a design due to product failures. DRBFM is applied during change management when the entire enterprise is involved in business decisions. Companies with formal change management systems can include DRBFM to support or reject a proposed change as part of a technical change review process. DRBFM lends structure to a technical review because it occurs before resources are brought together for a change review board or change committee (change approver). It allows the engineer (change owner) and the engineering manager (change leader) to dig for hidden problems before a change review board makes a decision about implementing the change. Since the DRBFM scope is defined by change points, the change owner and change leader can be highly productive in a short amount of time.