Have you ever launched a process, a workflow or an SOP that looked perfectly fine on paper but then reality hit you with a “Surprise, something broke again”?
I think we all lived through that moment. The moment when you ask yourself why no one saw the problem earlier and why we keep solving the same issues instead of preventing them.

This is where Design Review Based on Failure Mode becomes one of the smartest habits you can build into your work.

It is a simple idea. Before you release your design into the world, you sit down and ask a very honest question: What can fail here and what do we need to do now so it never becomes a real problem?

The beauty of this method is that it does not fight you. It does not need complex tools or long meetings. It just requires clarity, logic and a bit of humility. And the courage to look at your design through the eyes of risk, not optimism.

Let me show you a real example from the process improvement world. A new onboarding process. Something many companies struggle with, yet no one seems to take seriously until the damage is already done.

The Functions

Before anything else, I define what the process must actually do.

• Collect the new joiner data.
• Provide system access.
• Assign equipment.
• Schedule the mandatory trainings.
• Prepare the first week plan.
• Give clarity to managers and HR.

If a process cannot do these things, it is not an onboarding process. It is a chaos generator.

Where Things Can Fail

Design Review Based on Failure Mode starts with an uncomfortable but necessary truth. Anything can fail.

• You can miss important data.
• Access can be created late.
• Equipment can be wrong.
• Trainings can be forgotten.
• Managers can ignore their responsibilities.
• Stakeholders can follow their own version of the process.

I have seen all of this in real life. Probably you did too.

Why These Failures Happen

Failures are not random. They come from causes that repeat themselves.

• Forms without validation rules.
• No accountability.
• Backlogs in IT.
• Unclear responsibilities.
• Manual steps that depend on memory.
• Processes that live only in PowerPoint, not in people’s minds.

Once you understand the cause, you understand how to remove the future pain.

The Real World Impact

Every failure has a cost.

• Contract delays.
• Frustrated new joiners.
• Loss of productivity.
• Rework and unnecessary spending.
• Compliance risks.
• Teams starting their relationship with the company in confusion.

This is the moment when everyone suddenly cares. But at this stage, it is usually too late. The damage is already done.

What We Can Do Before Launching the Process

This is the heart of the method.

• Mandatory fields and clear validation rules.
• Standard equipment bundles.
• Automatic ticket creation for access.
• SLA and reminders.
• A manager template for the first week.
• A communication plan and an SOP that is actually followed.

These simple actions transform a fragile design into a stable one.

The Final Picture

Here is how a Design Review Based on Failure Mode looks in a structured form.

Function: collect data
Failure: missing or incorrect data
Cause: unclear form, no validation
Impact: contract issues and delays
Action: validation rules and mandatory fields

Function: provide access
Failure: late access
Cause: backlog, unclear responsibility
Impact: new joiner cannot work
Action: automated ticket, clear SLA

Function: assign equipment
Failure: wrong equipment
Cause: manual selection, outdated inventory
Impact: delays and cost
Action: predefined bundles and inventory sync

Function: schedule training
Failure: training not scheduled
Cause: manual step, no reminder
Impact: compliance risk
Action: automation and reminders

Function: first week plan
Failure: missing plan
Cause: managers unaware
Impact: low engagement
Action: template and reminder email

Function: overall clarity
Failure: people ignore process
Cause: poor communication
Impact: inconsistent onboarding
Action: communication, RACI, SOP

Why This Matters

Good design is not only about creativity or structure. It is about foresight. Design Review Based on Failure Mode forces you to imagine the version of reality you usually avoid.
Not the ideal version, but the honest version.

• It protects your future time, your sanity and your reputation.
• It reduces rework.
• It increases trust in your processes.
• It saves teams from frustration they will never even know existed.

If there is one habit worth adding to any design work, it is this one. It keeps you out of trouble and makes your processes not only beautiful but strong.