Design Review Based on Failure Mode (DRBFM) Course

Design Review Based on Failure Mode (DRBFM) Course

1. Design Review Based on Failure Mode Dr. Rauf Tailony © Ben Tolon University 2020

2. Introduction DRBFM: Design Review Based on Failure Mode Dr. Tatsuhiko Yoshimura

3. Introduction DRBFM == Preventive Maintenance DRBFM== Capturing Change Change = Opportunity/Challenge

4. Introduction Change is a must to stay alive in the market! If you don’t change; you will be changed

5. Introduction DRBFM makes sure the change is delivered without loosing quality.

6. Objectives Understanding why we use DRBFM Knowing how to effectively implement DRBFM Determine most beneficial techniques in holding DRBFM practices

7. Outline Overview and Value of DRBFM Project Milestones & Requests DRBFM Approach Prep/Support Tools & Exercises DR Participant List Request to EDs; DRBFM Resources When & How Concern Appears Design Actions Taken to Prevent Concern How to Hold DRBFM Meetings; DR Guidelines Summary

8. DRBFM Why We do DRBFM? Change is needed. Change creates Risk. We need processes to identify and reduce Risks. Risk in DRBFM- “The probability that a change point will trigger a negative outcome” Goal of DRBFM? To produce a robust design. Robustness - “Ability of a part to function as intended under unpredictable environmental conditions or customer usage” DRBFM is a mindset that is applicable to all stages of the Product lifecycle.

9. DRBFM Structure [GD] 3 Good design, Good discussion, Good design review(Dissection => Find problems) A collaborative approach towards the design process to identify problems and develop sustainable, robust solutions. For well designed systems; problems happen with changes (intentional and incidental) [GD] 3 Helps identifying these changes Good design: Don't change a good/robust design/process (fundamental principle of reliability). …but, change is inevitable. Therefore, have Good discussions: If changes must be made, involve others in discovering potential problems. Collaborative dissection to find hidden problems. …by having Good design reviews: Study the changes to identify and eliminate potential failure modes.

10. DRBFM Structure MB “ Mizenboushi ” is a mindset to proactively and predictively address all direct and indirect potential aspects of a problem to prevent failures == Proactive problem prevention

11. Proactive Prevention Cycle

12. Proactive Prevention Cycle

13. Approach to Quality

14. Proactive Prevention Cycle

15. New Design = Good Design DRBFM adopts the GD3 process to ensure that “New Design” = “Good Design”

16. New Design = Good Design?

17. DRBFM Overview Structured method to identify critical discussion points in preparation for Design Review (DR) Focus on “ CHANGED POINTS ” – Visualization and analysis by critical thinking Active discussions and comparisons with similar or previous models to detect as many potential problems as possible OUTPUT: Robust design, improved illustration

18. DRBFM Benefits Manage risk from changes Promote robust design mindset by leveraging experience Robust = insensitive to variation PROACTIVE PREVENTION: Predicting potential future problems and resolving them before they occur.

19. Design Change Problem 360 view ECU Module overheating Design change point

20. Design Change Problem Dimmer switch abrasion and melting Design change point

21. DRBFM in Development

22. DRBFM Procedure Overview

23. DRBFM Worksheet Visualize changes in both part and part environment (surrounding parts, usage conditions, etc.) Think carefully and deeply about potential concerns Clarify concerns and causes and prepare for DRBFM Discuss the documents deeply with the Experts and professionals

24. DRBFM Impact

25. DRBFM Targets and Milestones

26. Milestones Level check sheet for DRBFM Purpose: Measure quality of DRBFM application including depth and breadth of design information 6.0 total scale; 0.25 increments Pre-DR by SE Release ≥2.5/4.0 (shaded portion) Final by Genzu Release ≥4.0/6.0 Certified DRBFM Expert role – Guide the process to achieve target – Official level check score reporting – Submit to PDO for milestone reporting

27. DRBFM Part selection 100% of parts considered for DRBFM • Tech Notice (target issue 1 month after project start) • Sorting Sheet completed by ED/ES 1 week prior to Z-led consensus meeting • Consensus meeting w/ related divisions (target completion by K4 start)

28. DRBFM Approach Design engineer(s) think objectively about changes and part function, to identify and propose predictions for potential concerns. • Design engineer(s) obtain feedback and advice from knowledgeable experts, to ensure all other concerns are identified and addressed.

29. Design Review Preparation Use DRBFM worksheet to visualize assemblies and design parts with related function of each part and important properties. • Clearly visualize the potential problematic part or segment to the DR members.

30. DRBFM Worksheet Goals System visualization. Capturing changed points. Problem Finding or prediction.

31. Worksheet Process Change Identification Concern Discovery Root Cause Analysis Pre-DR

32. DRBFM Flow 1. Visualize

33. DRBFM Flow 1. Visualize Visualize the systems and related details. Showcase old design (baseline) vs. new design. More detailing for complex assemblies. Include surrounding parts (system subcomponents. Include direct and indirect changes.

34. DRBFM Flow 2. Hierarchy Diagram System Assy parts Sub- Assy parts Individual Parts Reference from exploded view List of components Category changes

35. DRBFM Flow 3. Change List System Assy parts Sub- Assy parts Individual Parts Reference from exploded view List of components Category changes Baseline New

36. DRBFM Flow 4. Function List System Assy parts Sub- Assy parts Individual Parts Reference from exploded view List of components Function Additional Functions

37. DRBFM Flow 4. Function List List functions at system’s level and then at part’s level. Include design characteristics when possible. Consider system and parts at all phases of product life. Apply Functions diagram to organize concerns based on changes in the Change matrix .

38. DRBFM Flow 4. Function List Notes: Understand the functions to identify potential failures. Define the function and purpose of each component in the system. Include the part interaction with the surrounding parts.

39. DRBFM Flow 5. Change Matrix List of components Category Baseline New List of Functions F1 F2 F3 C1 --- --- --- O A# X C2 --- --- --- X O A# C3 --- --- --- A# O X C4 --- --- --- O X O C5 --- --- --- A# X O Change Matrix

40. DRBFM Flow 5. Change Matrix Concern discovery: Find the potential failure mode by studying the interaction between the change points and the functions list.

41. DRBFM Flow 5. Change Matrix

42. DRBFM Flow 5. Change Matrix

43. DRBFM Flow 5. Change Matrix Potential Concern Example:

44. DRBFM Flow 5. Change Matrix Potential Concern Discovery: Interactions should be carefully considered for both past problems and those previously unseen. Include a note of the conditions, phenomena, timing of the event for future reference (root cause). Seek input from experienced members.

45. DRBFM Flow 6. DR Members List Participants 8/5/2019 8/15/2019 8/20/2019 8/21/2019 Category Company Name / Department Participant Name Title Invited (O: YES) Attended (O: YES) Invited (O: YES) Attended (O: YES) Invited (O: YES) Attended (O: YES) Invited (O: YES) Attended (O: YES) Own Department O O O O O O O O Function/ Part SHUSA                         Area AE/TA                         Supplier O O O O O O O O Responsible Expert               Related Design Engineering Dept.               Testing Dept.               Materials Engineering              

46. DRBFM Flow 6. DR Members List Preparation for Design Review: Visualize potential concerns identified by the change matrix. Create A-Rank list and 5why (root cause analysis) of each concern. Discuss with the DR experts the possible ways to resolve/avoid the concerns.

47. DRBFM Flow 7. A-Rank Worksheet Part Name/ Change Point Requirement/ Function Concern (Failure Mode) When & How concern appeared (Root Cause) Effect on Customer Design Actions Taken to Avoid the Concern Recommended Actions

48. DRBFM Flow 8. [ 5 Why] Worksheet

49. DRBFM Flow 8. [ 5 Why] Worksheet

50. Proactive Problem Prevention Systematic Approach Visualize Changes. Think deeply about potential concerns. Clarify concerns and causes. Discuss concerns with experts. Reflect preventive measures on design and manufacturing.

51. Building A Design Story Identifying changes. Identifying general functions. Identifying relationships and general concerns. Arranging the changes. Detailing the functions. Developing problem(s) statement(s).

52. Identifying Changes 1 2 3 4 Visualize parts and surroundings Breakdown assemblies and sub-assemblies Detail changes Compare “Old” vs. “New” models

53. Arranging Change Group items in “change comparison list” column by system, assembly, component. Include an advanced level of details. Include the reason behind the change (Why we wanted to move from “Old” to “New”. Follow top down approach in detailing (e.g. Assembly, sub-assembly, part, components)

54. Arranging Change Ex.

55. Identifying Functions Identify basic purpose of each system, assembly, component. Identify all other functions considering entire part life (all customers). Identify function at interface with surrounding parts. Generalize (capture the big picture)

56. Detailing Functions List the details of generalized descriptions. Add measurable parameters for evaluation. List criteria components (e.g. items to measure, record, inspect)

57. Detailing Functions Ex.

58. Identifying Relationships Every interaction should be carefully considered for both past problems and those previously unseen. Include a note of the conditions, phenomena, timing of the event for future reference (root cause analysis). Seek input from experienced members.

59. Develop A Problem Statement

60. Writing A Problem Statement Concern Problem statement requires Failure phenomenon e.g. Fuel Tank wall cracks at corner “x” at high speeds Fuel tank welding line separates At high temperatures Failure Defined When How Where

61. Arranging Design Story

62. What is Root Cause Analysis? Tracing the problem all the way to the source. Described by the depth where an intervention could be implemented to prevent the outcome (recurrence prevention). DRBFM Application → Potential causes considering Robust Design.

63. Root Cause Identification

64. Root Cause in DRBFM Problem Statement Failure phenomenon For parts and components When in part life Where (area of failure on part) Causes “Root Cause” Defining how by asking why Possible conditions and circumstances Different perspective and assumptions Environment impact on design and manufacturing

65. Root Cause in DRBFM

66. Steps to Avoid Concerns Root Cause Steps to avoid concern Undefined tolerance Define tolerance Low material stiffness Increase material stiffness Unclear position Define position clearly (x, y, z)

67. Potential Causes Main types of causes: Control Parameters with adjustable nominal values. Design parameters Process variables Noise Sources of variability (internal and external to the systems) Environment Customer use Process variations

68. Root Causes Tips Use simple and direct description. Ensure simplicity and clarity through detailed explanation. Locate controlled factors versus uncontrolled factors. Identify potential causes from various perspectives.

69. Root Causes Tips Address each root cause with Design evidence/ engineering studies: Design check sheets. Benchmarking results. Hand calculations with predicted safety margins. Link each identified cause (control). Show completed items (not future plans). Be quantitative to clearly satisfy function and requirement. Cautious use of CAE by including inputs, assumptions, boundary conditions and results.

70. DRBFM Process Summary Change Visualizing Old vs. New Design Change Comparison List Hierarchy Diagram Change Matrix DR Participants List ‘A’ Rank Worksheet Root Cause Analysis [5 Why] DR Meeting (s) DRBFM Scoring Sheet Durable Product Functions List

71. DRBFM Worksheet DRBFM Worksheet Template

72. Mechanical DRBFM Example Mechanical DRBFM Worksheet Product: VS.

73. Electrical DRBFM Example Electrical DRBFM Worksheet Product: VS.

74. Software DRBFM Example Electrical DRBFM Worksheet Product: VS.

75. System DRBFM Example Electrical DRBFM Worksheet Product: VS.

76. Typical Failure Modes |Electrical

77. Typical Failure Modes |Electrical

78. Typical Failure Modes |Software

79. Typical Failure Modes |Software

80. DRBFM Checklist

81. DRBFM Checklist

82. DRBFM Checklist

83. DRBFM Checklist

84. DRBFM Checklist

85. DRBFM Checklist

86. DRBFM Checklist

87. DRBFM Checklist

88. DRBFM Checklist

89. DRBFM Checklist

90. DRBFM Flowchart Summary

91. DRBFM Flowchart Summary

92. DRBFM 28 Steps Process

93. DRBFM 28 Steps Process

94. DRBFM 28 Steps Process

95. DRBFM 28 Steps Process

96. Reference Forms

97. Reference Forms

98. Reference Forms

99. Reference Forms

100. Reference Forms

101. Reference Forms

102. Reference Forms

103. Reference Forms © Ben Tolon University 2020