Design Review Based on Failure Mode: How Toyota Engineers Use an Advanced Model of FMEA to Improve Product Reliability (Toyota’s GD3)
About this ebook
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.
About the author
Mohammed Hamed Ahmed Soliman is an industrial engineer, consultant, university lecturer, operational excellence leader, and author. He works as a lecturer at the American University in Cairo and as a consultant for several international industrial organizations.
Soliman earned a bachelor of science in Engineering and a master’s degree in Quality Management. He earned post-graduate degrees in Industrial Engineering and Engineering Management. He holds numerous certificates in management, industry, quality, and cost engineering.
For most of his career, Soliman worked as a regular employee for various industrial sectors. This included crystal-glass making, fertilizers, and chemicals. He did this while educating people about the culture of continuous improvement.
Soliman has lectured at Princess Noura University and trained the maintenance team in Vale Oman Pelletizing Company. He has been lecturing at The American University in Cairo for 8 years and has designed and delivered 40 leadership and technical skills enhancement training modules.
Soliman is a member at the Institute of Industrial and Systems Engineers and a member with the Society for Engineering and Management Systems. He has published several articles in peer reviewed academic journals and magazines. His writings on lean manufacturing, leadership, productivity, and business appear in Industrial Engineers, Lean Thinking, Industrial Management, and Sage Publications. Soliman’s blog is www.personal-lean.org.
