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Toyota's Advanced GD3 Method: Going Beyond FMEA to Build Defect-Free Products
Most engineers know FMEA (Failure Mode and Effects Analysis). But fewer know that Toyota developed an advanced model that goes further. Their engineers created DRBFM - Design Review Based on Failure Modes, founded on the philosophy of GD3 Good Design, Good Discussion, Good Analysis.
This book explains how Toyota uses DRBFM as a practical extension of FMEA during the design phase, where up to 80% of product quality is determined. Instead of repeating a generic FMEA, DRBFM zeroes in on design changes, asking: What could go wrong because of this change?
What you'll learn:
The history of FMEA and why Toyota created DRBFM. The GD3 philosophy: how Good Design, Good Discussion, and Good Analysis work together. A clear comparison of FMEA vs. DRBFM - where they overlap and how Toyota's method goes beyond. Step-by-step FMEA refresher to build the foundation. Case studies (fire extinguisher, electrical steering, car engine) showing DRBFM applied in practice. Worksheets and examples to help you run your own design reviews.
Whether you are a design engineer, quality manager, lean six sigma practitioner, or reliability professional, this book gives you the Toyota-proven toolset for embedding quality at the design stage - reducing defects, lowering cost, and creating products that last.
Key difference: FMEA looks everywhere for risk. DRBFM focuses the discussion exactly where design changes happen, preventing failures before production.
If you've ever thought "FMEA is useful, but too broad" - DRBFM is the focused, Toyota-proven answer.
About the Author Internationally Recognized Lean Expert Dr. MHA Soliman is a Lecturer in 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. He brings decades of academic and consulting experience and is recognized as a leading expert in organizational performance, institutional transformation for total quality systems, and the quality of public services. He has authored over 100 peer-reviewed scientific publications and works as an executive consultant, author, and researcher specializing in management, continuous improvement, and service development.
