Enhancing Design Quality: JMAC's Insight for Manufacturing Sector Challenges

In the latest issue of Nikkan Kogyo Shimbun's "Mechanical Design" magazine, Japan Management Association Consulting (JMAC) has contributed an insightful article entitled "Understanding the Basics and Approaches of FMEA/DRBFM". This piece is designed to bolster the quality of design in the manufacturing industry and to prevent issues before they arise. It features contributions from JMAC’s seasoned consultants and Akiya Suzuki, CEO of the AI-driven PLM company, Things.

The Experts Behind the Contributions

The article aggregates the expertise of JMAC's Principal Consultant Shigeyoshi Kashiwagi, Senior Consultant Yasushi Tsujimoto, and Chief Consultant Shota Nakagawa, alongside Akiya Suzuki. Each contributor offers valuable insights aimed at resolving common problems associated with market disruptions and the overwhelming challenges posed by outdated FMEA (Failure Mode and Effects Analysis) and DRBFM (Design Review Based on Failure Mode).

They suggest practical solutions to these prevalent issues in development and design settings, such as redefining the concept of "collective wisdom" within organizations, reducing risks in the manufacturing process, and utilizing advanced AI for next-generation preventive activities.

The Current Landscape of Design Quality in Manufacturing

Japan's manufacturing industry is currently facing significant structural challenges, primarily attributed to the retirement of skilled technicians and the slow transfer of skills to younger employees. In bustling design environments, tools like FMEA are increasingly viewed as mere paperwork rather than vital processes for identifying and managing potential risks.

To counter this trend, it is essential to develop a quality assurance system that does not rely solely on individual skills but rather leverages the collective power of the organization. JMAC believes that a new directive is crucial to navigate the complexities of today’s system products by integrating years of field support expertise with the latest digital technologies.

Article Structure Overview

This comprehensive article comprises five chapters, covering aspects from design to manufacturing and digital utilization.

Chapter 1 & 2: FMEA/DRBFM Fundamental Understanding

The initial chapters elaborate on the fundamental understanding and operational points of FMEA and DRBFM. They highlight the importance of adapting robust strategies to manage diverse failure risks tailored to the specific characteristics of one's products. This section tackles both reliability issues and various potential faults to ensure better preparedness in actual practice.
(Contributors: Principal Consultant Shigeyoshi Kashiwagi)

Chapter 3: Utilizing FMEA in Process Design

Focusing on process design, this section categorizes risks in the manufacturing process and underscores the necessity of choosing the right methodologies according to specific objectives. Important points on enhancing practical capabilities in process FMEA, viewed through the lenses of value addition and loss, are detailed here.
(Contributors: Senior Consultant Yasushi Tsujimoto)

Chapter 4: Advanced Cases from the Automotive Industry

This chapter offers insights based on leading instances from the automotive industry, outlining foundational developments to avert procedural fallacies and standardizes technical knowledge. It marks a proactive step in avoiding the pitfalls of conventional methodologies.
(Contributors: Chief Consultant Shota Nakagawa)

Chapter 5: Transformative Impact of AI on Preventive Activities

The final chapter discusses how AI can revolutionize preventive efforts. By employing the Engineering Chain Foundation "PRISM," it proposes a collaborative workflow between humans and AI to swiftly generate initial drafts of concerns based on vast archives of technical documents.
(Contributors: Akiya Suzuki, CEO of Things)

About the Authors

Shigeyoshi Kashiwagi

As a Principal Consultant at JMAC, Kashiwagi has consistently supported technology departments since joining the firm. His consulting focus includes business restructuring, system implementation in manufacturing, and enhancing design quality across various sectors, including automotive and precision machinery.

Yasushi Tsujimoto

Senior Consultant Tsujimoto specializes in solutions for development, procurement, and production challenges across industries such as automotive components and pharmaceuticals. His work emphasizes the construction of sustainable systems to elevate QCD (quality, cost, delivery) effectively.

Shota Nakagawa

Chief Consultant Nakagawa provides consultancy in project management and cost reduction in the design and development sectors within manufacturing. He also supports initiatives related to SDGs, aiding organizations in various sustainability assessments.

About JMAC

Japan Management Association Consulting, based in Minato, Tokyo, offers comprehensive consulting services crossing multiple functional areas including strategy, R&D, production, and supply chain management. Founded in 1980, JMAC continues to lead in providing effective solutions in today’s complex manufacturing landscape.