Introduction to Design Review Based on Failure Modes (DRBFM)     New!


I.D.# C1359Printable Description
Duration: 1 Day
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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. Even though a cross-functional team looks at how changes could potentially diminish a product’s function and impact the customer’s experience, the team’s major role is to support the engineer in development of his or her design. Detailed countermeasures and follow-up actions are identified to ensure that potential concerns are prevented with engineering evidence (data).

DRBFM is an analytical process used to address design and process changes throughout the product development process. The basis of the process is the front loading of the engineering efforts to clearly define the impact of change and eliminate the need for extended engineering activity after production launch. The process is inclusive of all activities that impact quality, 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. This training module will provide information on how and when these activities are linked.

This one-day training will explain all phases of the DRBFM methodology and provide details on how to accomplish the specific steps. With the Design Review Based on Failure Modes (DRBFM) and Design Review Based on Test Results (DRBTR) Process Guidebook that is bundled with the course, the instructor will provide specific information on each step. Formats, examples, notes and homework slides will be used to illustrate the defined steps of the SAE J2886 DRBFM Recommended Practice and the AIAG DRBFM Reference Guide. Similarities in content between DRBFM and FMEA will be discussed; however the focus will be on conducting DRBFM methodology.  

This DRBFM training will provide roles and responsibilities of management, design engineers, manufacturing engineers, DRBFM and technical experts. Those interested in DRBFM will benefit from understanding the rationale behind this methodology and learn to guide teams through the paradigm shifts and mind-set that are needed. Those interested will learn how DRBFM supports the activity of the engineer, company objectives and customer expectations.

Learning Objectives
After completing this program, you will be able to:

  • Outline the fundamental steps of DRBFM methodology, including:
    • An understanding of the DRBFM Culture
    • DRBFM Plan and analysis requirements
    • Necessary preparation feeding DRBFM analysis
    • The two phases of DRBFM analysis
    • Documentation of design, validation and manufacturing actions
    • Feedback loop into engineering knowledge documents
  • Explain the intent and format of the DRBFM worksheets
  • Predict what it takes to gain and maintain proficiency and consistent application of the methodology
  • Locate answers to most DRBFM questions

Who Should Attend
Product engineers, manufacturing engineers, quality engineers, supplier quality engineers, validation and test engineers, and facilitators, trainers and consultants in all industries. This seminar will benefit new engineers, advanced and senior engineers and managers who must participate in FMEA's and DRBFM.

Topical Outline
Day One (8:30am – 4:30pm)

  • 8:30am – 9:00am: Introduction and course objectives
    • DRBFM Process Competitive Assessment - Toyota Process
  • 9:00am-9:45am: Step One: Preparation Documents
  • 9:45am-10:00am: Break
  • 10:00am-11:15am: Preparation Documents Exercise and Review
    • Participants can bring either DFMEA or DRBFM foundation documents of a current project (boundary diagram, functions and specifications, changes and current issues) for review during this session
  • 11:15am-Noon: Step Two: Change Point Analysis
    • How to complete DRBFM analysis
    • Forum One: Change Point Detail and Functions - System, Sub-system and component
  • Noon: Lunch
  • 1:00pm – 3:30pm (Break included): Change Point Analysis…continued
    • Forum One: Document Change Point Analysis (each student): Concerns; Causes; Effects; Importance; Design Countermeasures; Actions to gain knowledge - Defined by engineer
  • 3:30pm – 4:30pm: Step Three: Design Review and Step Four: Action Results
    • Including an introduction to Design Review Based on Test Results
  • 4:30pm How to Audit your DRBFM and Wrap up

    Instructor(s): Bill Haughey
    Bill Haughey Bill Haughey is a respected consultant and instructor in the areas of Failure Modes Effects Analysis, Design for Manufacturability and Assembly, Design Review Based on Failure Modes, Design Review Based on Test Results, and other GD3 methodologies. He is a current member of the issuing committee of the SAE J1739 FMEA standard, SAE Automotive Quality and Process Improvement Committee; the SAE Automotive Electronic Systems Reliability Standards Committee; and the AIAG FMEA Fourth Edition Recommended Practice Committee. Mr. Haughey was recently approved to lead the development of a new SAE DRBFM Recommended Practice (J2886). Mr. Haughey formerly worked for GM, where he held various managerial, manufacturing, and engineering positions including Process Lead and Supervisor for FMEA and DFM/A. While at GM, Mr. Haughey also supported Tatsuhiko Yoshimura in the global implementation of the GD3 (DRBFM) methodology. Yoshimura considers Mr. Haughey to be a subject matter expert in the GD3 methodologies, including DRBFM and DRBTR. Mr. Haughey received a B.S. degree from the University of Michigan and M.S from Central Michigan University, and has the following certifications: Black Belt in GD3 (DRBFM and DRBTR); Master Design for Manufacturability and Assembly Engineer; and Certified Internal Auditor.

    Fees: $780.00 ; SAE Members: $630.00 - $710.00

    .7 CEUs
    You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

    For additional information, contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at