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This paper presents an approach to product design and development based on function failure avoidance, using of series of well known engineering tools including Function Fault Tree Analysis, P-Diagram and Design Verification. A 4-step function failure mode avoidance process is presented. The use of the engineering tools in an integrated and synergistic manner to achieve robust and reliable product design is illustrated by considering information flow within an automotive case study. The central role of FMEA within the process is described. The authors’ experience of using the process is discussed.

The quality of the output generated by a team is directly influenced by how well the team works together. Despite the complexity of the team system, within a typical Design for Six Sigma (DFSS) project the consideration given to the team process is often disproportionately small in comparison to that paid to the technical aspects of the project. This paper presents an efficient approach to teamwork within an engineering design context such as a DFSS project, in which team skills are modelled on DFSS technical processes allowing team members to learn both technical and teamwork skills within the common context of the technical process. DFSS engineering tools used within the framework of Failure Mode Avoidance are used to identify key potential failure modes in the team process and their effects and causes. A series of effective and efficient countermeasures to the team process failure modes are introduced as straight forward and easy to use interlinking teamwork tools.

This paper presents a design for reliability methodology based on the DfSS DCOV process, applied to the development of a cost effective timing chain drive for a four cylinder diesel engine. A CAE model for the timing chain drive was used to study the distribution of the chain loads, which provided an essential input both for the concept selection stage and for the development of a reliability model for the timing chain. A DoE study on the CAE model aimed at investigating the significant factors for chain load variability lead to a reliability improvement achieved by reducing the variability in the chain load through revising the tolerances for the sprocket tooth profile. The paper demonstrates the efficiency of the process and the usefulness of computer simulation in achieving reliability and robustness enhancement while reducing design and development time and costs.