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    Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)
    Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)
    Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)
    Ebook85 pages31 minutes

    Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)

    By Mohammed Hamed Ahmed Soliman

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    About this ebook

    Toyota doesn't just make high-quality products; they also have a process for making sure everything they do is high-quality. Next time you want to say Toyota isn't that great, think about how their way of doing things could help you make better quality products.

    Reliability is about having a product or service that can be trusted is really important for making customers happy. This means that the product will work the way the customer wants it to, and it will keep working well for a long time. Quality experts are basically saying that it is very important to focus on improving quality in all aspects of a business. They believe that businesses should prioritize quality in order to be successful. The more complicated the product is, the harder this task gets.

    Before World War II, the military, aerospace, and aircraft industries used the failure mode and effect analysis (FMEA) approach. Toyota then invented its production system after the war. FMEA has been around since the middle of the 20th century, especially in the aerospace and military industries. FMEA was made in the 1940s and used by the U.S The military works to find and fix problems in production before they happen. The method worked well, so NASA used it for different projects like Apollo and Voyager in the 1960s.

     

    Nowadays Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself.

    The DRBFM methodology was created by Tatsuhiko Yoshimura, who is an expert in quality and a professor at Kyushu University in Japan. Yoshimura understood that making changes without the right documents can cause design problems. He used the idea of preventing problems before they happen to come up with his own way of thinking called DRBFM.

    LanguageEnglish
    Publisherpersonal-lean.org
    Release dateApr 7, 2024
    ISBN9798230468820
    Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)
    Author

    Mohammed Hamed Ahmed Soliman

    Dr. Mohammed Hamed Ahmed Soliman is an internationally recognized Lean expert, author, and university lecturer. He has published over 100 books and articles on Lean thinking, quality systems, and industrial excellence. He currently teaches Industrial Engineering and Management Systems at the American University in Cairo, an Executive Advisor and a member of the Advisory Committee of the IEOM International Society, and consults for global organizations across manufacturing, public services, and education. With nearly two decades of academic and professional experience, Dr. Soliman has trained professionals across the Middle East, including engagements with Princess Nourah University in Saudi Arabia and Vale Oman Pelletizing Company. He has designed and delivered over 60 leadership and technical development programs, helping organizations build a culture of continuous improvement and operational excellence. Earlier in his career, he worked in various industrial sectors including crystal-glass manufacturing, fertilizers, and chemicals, while educating teams on the Toyota Production System. He has led numerous lean transformation projects, delivering measurable results and uncovering substantial cost savings by targeting waste across production and service environments. His lectures and training materials have reached over 200,000 learners via SlideShare, and his research is ranked among the most downloaded papers on the Social Science Research Network (SSRN) by Elsevier. Dr. Soliman holds a BSc in Engineering, a master's in Quality Management, and postgraduate degrees in Industrial Engineering and Engineering Management. He also holds certifications in quality, cost, and operations management. He is a member of the Institute of Industrial and Systems Engineers (IISE) and the Society for Engineering and Management Systems (SEMS). His insights have been featured in SAGE Publications, Industrial Management, Lean Thinking, and other peer-reviewed platforms.  

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      Book preview

      Design Review Based on Failure Mode - Mohammed Hamed Ahmed Soliman

      ​Toyota

      Toyota doesn't just make high-quality products; they also have a process for making sure everything they do is high-quality. Next time you want to say Toyota isn't that great, think about how their way of doing things could help you make better quality products.

      Reliability is about having a product or service that can be trusted is really important for making customers happy. This means that the product will work the way the customer wants it to, and it will keep working well for a long time. Quality experts are basically saying that it is very important to focus on improving quality in all aspects of a business. They believe that businesses should prioritize quality in order to be successful. The more complicated the product is, the harder this task gets.

      ​History

      Before World War II, the military, aerospace, and aircraft industries used the failure mode and effect analysis (FMEA) approach. Toyota then invented its production system after the war. FMEA has been around since the middle of the 20th century, especially in the aerospace and military industries. FMEA was made in the 1940s and used by the U.S The military works to find and fix problems in production before they happen. The method worked well, so NASA used it for different projects like Apollo and Voyager in the 1960s.

      Nowadays Six Sigma's project team use FMEA in the Analyze stage of DMAIC because extraordinary quality is not only designed into the product, it is designed into the development process itself.

      FMEA is a risk assessment tool with a 1-10 scoring scale. A one indicates low risk, while a ten indicates extremely high risk. FMEA is an effective method for development and manufacturing organizations to reduce potential failures throughout the product lifecycle.

      The FMEA process is explained by four parts:

      Failure modes: This means the different ways that something can stop working.

      Failure causes: FMEA looks at how things can go wrong to find out why they happened.

      Failure mode analysis: Once we

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