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Quality by Design

Quality by Design is a systematic approach to product development that emphasizes meeting customer expectations through cooperation and communication between cross-functional teams. It aims to design products with ease of producibility and customer satisfaction by involving stakeholders from various areas simultaneously early in the process. Implementing Quality by Design requires preparation, dedicated project teams, regular communication, and tools to facilitate organizational and product development goals of reduced costs and time to market.

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26 views45 pages

Quality by Design

Quality by Design is a systematic approach to product development that emphasizes meeting customer expectations through cooperation and communication between cross-functional teams. It aims to design products with ease of producibility and customer satisfaction by involving stakeholders from various areas simultaneously early in the process. Implementing Quality by Design requires preparation, dedicated project teams, regular communication, and tools to facilitate organizational and product development goals of reduced costs and time to market.

Uploaded by

Moraxell. GG
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Quality By Design

Definition of:

Quality by Design is
the practice of using a
multidisciplinary team to
conduct conceptual
thinking, product design,
and production planning
all at one time.
A More General Definition
A Systematic approach
to integrated product development that emphasizes
response to customer expectations
and embodies
team values of cooperation, trust and sharing
in such a manner that
decision making
proceeds with large intervals of parallel working by all life-cycle
perspectives,
synchronized
by comparatively brief exchanges
to produce consensus. -- Joe Cleetus
The Easy Definition!!!

With a team to simultaneously design


and develop products that have

Ease of
Producibility
Customer
Satisfaction
Other Terms for Quality by
Design
⚫ Concurrent Engineering

⚫ Simultaneous Engineering

⚫ Parallel Engineering
People to Include on Your
Quality by Design Team
⚫ Specialist From Business
⚫ Engineering
⚫ Production
⚫ The Customer Base

and at appropriate times


⚫ Suppliers of Equipment, Purchased Parts
and Services
This Front End
Planning Leads to

Performance
(quality & time to market) Cost
(eliminates design
changes late
in project)

Communication
(more apt to stay flexible & eliminates
the “over the wall” mentality
Product Development Flow Diagram
Another View of a Quality Planning Process
Benefits of Quality by Design
⚫ Significant decrease in time to market
⚫ Faster product development
⚫ Better quality
⚫ Less work in progress
⚫ Fewer engineering change orders
⚫ Increased productivity
⚫ Reduced labor costs
⚫ Increased profits for the company
Quality by Design

Teams
❖Must have a variety of
backgrounds and expertise.
❖Must communicate!!
❖Must think outside the box-
stay flexible!!
Traditional Communication Flow Model
Quality by Design Communication Model
Implementation
Why Implement
⚫ Budgets are more critical today than
in past
⚫ 1970’s
– Fewer brands to choose from
– Price = Cost + profit amount
⚫ Today
– Design changes in product
development creates higher costs.
Why Implement
– Control cost by designing at the start of
a project

– Increased time in the design stage


• Changes in design stage cost 10 times more
than in testing stage
• Spending 10 times more creates the need
for development software EX: CAD/CAM
Why Implement

⚫ More time designing


results in a more
complete final product

⚫ Less Rework

⚫ Less waste of Materials


Why Implement
⚫ Fewer Design Changes + Shorter Lead
Times = Quicker Response to Customer’s
Needs

⚫ Lower Rejects and Scraps = Increased


Profits

⚫ Customer Returns decrease

⚫ Profit Margins increase


Key Concepts
⚫ Look at the whole product life cycle

⚫ Agree that organization has internal


and external customers and suppliers

⚫ Commitment to quality for the entire


process of making the product
Preparation for Implementation
⚫ Principles -
– Statement of principles that the
company operates on
⚫ Assessment -
– How the company currently operates
and the changes that will be made
⚫ Work Process -
– Define procedures for the new process
Preparation (continued)
⚫ Internal Organizational Changes -
– Define how reporting and management will
change
⚫ Supply Chain -
– Define how the supply chain will participate in
development of the project
⚫ People Systems -
– Define reward systems, goals and objectives
⚫ Technology -
– What new technology needs to be in place to
complete the project
Implementation
⚫ Start
– A Meeting with
everyone involved.

– Communication
between everyone
involved.

– Some companies
start with a “Pilot”.
Implementation
⚫ Benefits of Meetings
– Project members meet face to face and develop
personal relationships with internal and external
customers and suppliers.

– Everyone understands goals.

– Clear up misconceptions

– Answer questions
Implementation
⚫ Meetings
– Regular meeting should be set for reviewing the
project

– Exchange ideas and resolve complaints

– Time between meeting should be long enough for


questions to arise and short enough to make
design decisions
Implementation
⚫ Dedicated Project Teams
– Have a sense of togetherness

– Communication is established

– Each member knows the


capabilities of team members
Implementation

⚫ Flaws of Dedicated Project Teams


– Sense of stability and settling occurs

– Tend not to look for better ways to solve


problems and rely on past practices
Implementation
⚫ Co-Location
– Placing team members in same location

– Team stimulated to continuously find


solutions to problems with the project

– Increased communication and


continuous improvements
Implementation
⚫ Disadvantages of Co-Location
– Cost of moving and providing for
project team members

– Team members lose communication


with the department they came from

– Product in that department may suffer


Implementation
⚫ Computer Networks
– Allow team members to
communicate with the
department they came
from

– Communication with
resources and
applications
Implementation
⚫ Advantages of Computer Networks
– Eliminates cost of Co-Location

– Communication between team members


and outside consultants

– Records progress for managers and


accounting department
Implementation
⚫ Cost Increases
– Time and Money have to be considered before
applying the design
⚫ Cultural Changes
– Solutions require cultural changes before becoming
effective
– Through meetings, managers can slowly change the
culture of the organization
– After cultural changes, project facilitator may be
hired
Implementation
⚫ Implementation of Quality by Design is
a way to true quality by design.
The Tools

–A brief history
–Who uses them
–What they do
History of the Tools

⚫ Finite element analysis developed in the


50’s and 60’s
⚫ Aircraft manufacturers start using CAD in
late 1970’s
⚫ Many tools not available until late 1980’s
⚫ Today, small organizations are able to buy
personal computer software tools
Overview
⚫ Organizational Tools
– Improve communication and understanding
⚫ Product Development Tools
– Decrease product development time
⚫ Production Tools
– Improve quality of manufactured parts and
decreases production time
⚫ Statistical Tools
– Allow studying and targeting of variables effecting
design, testing, and production
Who Uses the Tools
⚫ Organizational Tools
– Everyone

⚫ Product Development Tools


– Engineering and Design Professionals

⚫ Production Tools
– Production Engineers

⚫ Statistical Tools
– Quality Engineers and Others when needed
Organizational Tools

⚫ TQM Philosophy
⚫ Computer Networks
⚫ ISO 9000 and ISO 14000
⚫ Total Productive Maintenance
⚫ Quality Function Deployment
⚫ Electronic Data Interchange
Product Development Tools
⚫ Computer-aided drafting software
⚫ Solid modeling software
⚫ Finite element analysis software
⚫ Parametric analysis software
⚫ Rapid prototyping techniques
⚫ Design for manufacture and assembly
techniques
⚫ Failure mode and effect analysis
Production Tools

⚫ Computer-aided Manufacturing
⚫ Computer numerical controlled tools
⚫ Continuous process improvement
⚫ Just-in-time production
⚫ Virtual manufacturing software
⚫ Agile manufacturing
Statistical Tools

⚫ Design of Experiments

⚫ Statistical Process Control


Other Considerations
⚫ Training is a must
– Requires money and time

⚫ Using the tools increases employee


retention and satisfaction
Misconceptions of
Quality by Design
❖It is NOT simultaneous design and production.
ALL designs are finalized BEFORE production
begins.
❖It is NOT a quick fix or magical formula for
success.
❖It does NOT require multiple testing of
products.
❖Should NOT be confused with TQM inspection
techniques.
Pitfalls to Avoid
❖ Don’t eliminate the old type sequential
engineering system too quickly.
❖ Avoid having an unobtainable schedule. Better
to be done early (longer predicted time) than to
be late (shorter predicted time).
❖ Avoid using tight tolerances and stringent
requirements.
❖ Avoid changing the product specs during the
design phase.
❖ Avoid using the low bidder.
❖ Avoid automating the product development
phase before it is simplified.
References
⚫ Besterfield, D. H., Besterfield, G. H., Besterfield-
Michna, C., & Besterfield-Sacre, M. 1999. Total
Quality Management. New York:Prentice Hall.
⚫ http://www.erim.org/cec/column/mar00.htm
⚫ http://www.erim.org/cec/column/nov96.htm
⚫ http://www.cerc.wvu.edu/documents.htm
⚫ http://www.icsassociates.com/index.html
⚫ http://www.amkor.com/services/quality/apqp.cfm

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