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
