Chapter 6 customer needs and manufacturing or service

Design for Quality and Product Excellence delivery requirements.

Product Development This is a series of steps that Innovation involves the adoption of an idea,
includes the conceptualization, design, development process, technology, product, or business model that
and marketing of newly created or newly rebranded is either new or new to its proposed application.
goods or services. Innovation is built upon strong research and
development (R&D) processes.
Six Phases of Product Development
1. Idea Generation - Develop concept Creativity - is seeing things in new or novel ways.
incorporating customer needs and
expectations Creativity tools, such as brainstorming and
2. Preliminary Concept Development - Study “brainwriting, ” aredesignedtohelp change the
new ideas for feasibility context in which one views a problemor
3. Product/Process Development -Evaluate opportunity, thereby leading to fresh perspectives.
design alternatives and determining
engineering specifications; test prototypes; TRIZ, a Russian acronym for the Theory of
develop, test, and standardize processes Inventive Problem Solving (TIPS)
4. Full-Scale Production - Release the product
to manufacturing or service delivery teams  Developed by a Russian patent clerk who
5. Market Introduction - Distribute to studied thousands of submissions, and
customers observed patterns of innovation common to
6. Market Evaluation - Market evaluation and the evolution of scientific and technical
customer feedback to initiate continuous advances.
improvements  He recognized that these concepts could be
taught, and he developed some 200 exercises
Concurrent Engineering to foster creative problem solving.
Concurrent engineering is a process in which all
major functions involved with bringing a product to 1946
market are continuously involved with product GENRICH ATLSHULLER
development from conception through sales. Theory of Inventive Problem Solving (TIPS)
Teoriya resheniya izobretatelskikh zadach
Design for Six Sigma
Design for Six Sigma (DFSS) represents a Detailed Design
structured approach to product development and a Detailed design focuses on establishing technical
set of tools and methodologies for ensuring that requirements and specifications, which represent the
goods and services will meet customer needs and transition from a designer’s concept to a producible
achieve performance objectives, and that the design, while also ensuring that it can be produced
processes used to make and deliver them achieve economically, efficiently, and with high quality.
high levels of quality.
Axiomatic design is based on the premise that good
DFSS Principal Activities design is governed by laws similar to those in
 Concept development natural science.
 Detailed design
 Design optimization Two classification of Axioms
 Design verification 1. Independence Axiom: good design occurs
when the functional requirements of the
Concept Development and Innovation design are independent of one another.
Concept development is the process of applying 2. Information Axiom: good design
scientific, engineering, and business knowledge to corresponds to minimum complexity.
produce a basic functional design that meets both
Quality Function Deployment (QFD)
  is a planning process to guide the design, Tolerance design involves determining the
manufacturing, and marketing of goods by permissible variation in a dimension.
integrating the voice of the customer  Narrow tolerances tend to raise
throughout the organization. manufacturing costs, but they also increase
 Through QFD, every design, manufacturing, the interchangeability of parts within the
and control decision is made to meet the plant and in the field, product performance,
expressed needs of customers. durability, and appearance.
 QFD benefits companies through improved  Wide tolerances increase material
communication and teamwork between all utilization, machine through put, and labor
constituencies in the value chain, such as productivity, but have a negative impact on
between marketing and design, between product characteristics
design and manufacturing, and between
manufacturing and quality control. The Taguchi Loss Function
Taguchi measured quality as the variation from the
The Four Linked Houses of Quality target value of a design specification, and then
1. Customer Requirements = Technical translated that variation into an economic “loss
Requirements function” that expresses the cost of variation in
2. Technical Requirements = Component monetary terms.
Characteristics
3. Component Characteristics = Process Taguchi assumes that losses can be approximated by
Operations a quadratic function so that larger deviations from
4. Process Operations = Quality Control Plan target correspond to increasingly larger losses.
Design for Reliability
Building the House of Quality Reliability is defined as the probability that a
1. Identify customer requirements. product, piece of equipment, or system performs its
2. Identify technical requirements. intended function for a stated period of time under
3. Relate the customer requirements to the specified operating conditions.
technical requirements.
4. Conduct an evaluation of competing Key elements:
products or services.  Probability
5. Evaluate technical requirements and develop  Time
targets.  Performance
6. Determine which technical requirements to o Two Types of Failure
deploy in the remainder of the  Functional Failure - failure
production/delivery process. that occurs at the start of
product life due to
Target and Tolerance Design manufacturing or material
Manufacturing specifications consist of nominal detects
dimensions and tolerances.  Reliability Failure - failure
 Nominal refers to the ideal dimension or the after some period of use
target value that manufacturing seeks to  Operating conditions
meet.
 Tolerance is the permissible variation, Reliability Concepts
recognizing the difficulty of meeting a target  Inherent reliability is the predicted
consistently. reliability determined by the design of the
o Nominal and Tolerance are cannot product or process.
combine always due to 5 M’S- Men  Achieved reliability is the actual reliability
& women, Materials, Machineries, observed during use.
Method’s and Measurement  Achieved reliability can be less than the
inherent reliability due to the effects of
Tolerance Design
 the manufacturing process and the Rating: 7-9
conditions of use. Severity: Serious impact on customer safety or
satisfaction
Design Optimization Occurrence: High probability of occurrence
Robust design refers to designing goods and Detection: Low chance of detection
services that are insensitive to variation in
manufacturing processes and when consumers use Rating: 5-6
them. Severity: Major impact on customer safety or
satisfaction
Robust design is facilitated by design of Occurrence: Moderate probability of occurrence
experiments to identify optimal levels for nominal Detection: Moderate chance of detection
dimensions and other tools to minimize failures,
reduce defects during the manufacturing process, Rating: 2-4
facilitate assembly and disassembly (for both the Severity: Minor impact on customer safety or
manufacturer and the customer), and improve satisfaction
reliability Occurrence: Low probability of occurrence
Detection: High chance of detection
DFMEA
Design Failure Mode and Effects Rating: 1
Analysis(DFMEA) – identification of all the ways Severity: Little to no effect
in which a failure can occur, to estimate the effect Occurrence: Unlikely to occur
and seriousness of the failure, and to recommend Detection: Will almost always be able to detect
corrective design actions.
Fault Tree Analysis
 Fault Tree Analysis (FTA), sometimes
called cause and effect tree analysis, is a
Elements of DFMEA method to describe combinations of
1. Failure modes - ways in which each conditions or events that can lead to a
element or function can fail. failure.
2. Effect of the failure on the customer- such  A cause and effect tree is composed of
as dissatisfaction, potential injury or other conditions or events connected by “and”
safety issue, downtime, repair requirements, gates and “or” gates.
and so on.  An effect with an “and” gate occurs only if
3. Severity, likelihood of occurrence, and all of the causes below it occur; an effect
detection rating - The severity rating is with an “or” gate occurs whenever any of
based on how serious the impact would be if the causes occur.
the potential failure were to occur.
4. Potential causes of failure-often failure is Design for Manufacturability
the result of poor design. DFM - the process of designing a product for
5. Corrective actions or controls – these efficient production at the highest level of quality.
controls might include changes, mistake
proofing, better user instructions, Example guidelines (see Table 7.1)
management responsibilities, and target 1. Minimize number of parts
completion dates. 2. Design for robustness
3. Eliminate adjustments
Scoring Rubric for DFMEA 4. Make assembly easy and foolproof
Rating: 10 5. Use repeatable, well-understood processes
Severity: Hazardous or potentially life-threatening 6. Choose parts that can survive process
Occurrence: Very high or almost certain probability operations
of occurrence 7. Design for efficient and adequate testing
Detection: Cannot detect or hidden defect 8. Lay out parts for reliable process completion
 9. Eliminate engineering changes

Design for Excellence

DFX - an emerging concept that includes many
design-related initiatives such as concurrent
engineering, design for manufacturability, design
for assembly, design for environment, and other
“design for” approaches
 Higher functional performance
 Physically Performance - user friendly
 Reliability - Durability
 Maintainability - Serviceability
 Safety -Compatibility,
o Upgradeability
o Environmental Friendliness
o Psychological Characteristics.
 Principles
o Constantly thinking in terms of how
one can design or manufacture
products better
o Focusing on “things done right”
rather than “things gone wrong”
o Defining customer expectations and
going beyond them
o Optimizing desirable features or
results
o Minimizing the overall cost without
compromising quality

Design Verification - sometimes verification is

required by government regulation or for legal
concerns.

Design Reviews
The purpose of a design review is to stimulate
discussion, raise questions, and generate new ideas
and solutions to help designers anticipate problems
before they occur.

Reliability Testing
Life testing – run devices until failure occurs
Accelerated life testing – overstress devices to
reduce time to failure
Highly accelerated life testing - focused on
discovering latent defects would not otherwise be
found through conventional methods.