In the study of validity of manufacturing process design, it is necessary to predict and prevent failures that would occur in designed processes and understand the weak points of the designed processes. In this paper, the application of the method to predict potential failures in process design based on reusable knowledge acquired from trouble reports on process design is described. Firstly, an example of DR (Design Review) conducted at the company the author belonged to and an activity for utilizing knowledge of failures which occurred due to poor process design are introduced and .the problems in these activities are described: Next, the activity at the company for utilizing structured knowledge of failures based on SSM (Stress-Strength Model) and the study on effective reuse of knowledge of process failures by SSM are introduced. Finally, man-hours required for acquiring structured knowledge of failures and the significance of the activity for utilizing structured knowledge are considered.