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

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.