Tokyo Electron(TEL) has adopted a front-loading approach to improve product quality. Specifically, we use the GD3 (GD cubed) management method of problem prevention to ensure thorough risk identification from the concept design stage. Using this method, the designer and reviewer review each stage from design and evaluation to full production and identify risks, focusing on changes from the previous designs.
When using the GD3 method, we adjust techniques and work environments to improve our ability to identify risks. To achieve a high quality review, we need high quality reviewers, so we request the participation of internal experts in the review process. At the same time, our basic rule is to assign additional people from each division to identify risks from many different angles. To improve the efficiency of discussions, we have created search tools to find past instances of problems and we use mind mapping to be more imaginative in risk identification.
Not only do we ensure full implementation of the GD3 review process internally, we also recommend the method to suppliers to help further enhance quality in the upstream processes.