1. Impacting Design Quality through Key Parameter Development & Management
Using KPD&M during Technology & Product Development Processes to Prevent Design Problems

2. Key parameters control financial consequences… through Y & s
Physical Law…
Y= f(X)
DY= f[DX + D(X*N)] + error XY Xs
Cp = (USL-LSL )/6s s
Cpkl = (Y-LSL)/3s
XY&s
XNoise
Cpku = (USL-Y)/3s Y T
$L(Y) = k[s2 + (Y-T)2]
…Financial Consequences
Intro to KPD&M, Copyright 2010, PDSS Inc.

3. What does the word “Key” mean?
Something that is…
New
Totally new to you & all your competitors, no one has fulfilled the requirement(s) or controlled the parameter(s) before – no experience!
Unique
The requirement(s) or parameter(s) have been fulfilled or controlled by others but not by you!
Difficult
The requirement(s) or parameter(s) are extreme & their fulfillment or control is very high in risk
Intro to KPD&M, Copyright 2010, PDSS Inc.

4. Things that are NOT “Key”…
Something that is…
Easy
Common
Old
These are functions, part specifications & mfg. functions that we place under normal Q.C. metrics
- Little or no SPC investment (low need to detect & prevent)
- Cp & Cpk checked periodically
- Use Six Sigma to react to problems in this area
Intro to KPD&M, Copyright 2010, PDSS Inc.

5. Refining the term - Key
A function, part or material characteristic can be designated as Key = Under Watch!
Functions occur in the product or process as it is transforming mass & / or energy… it is what the product or process does.
Inherent in the design of the product or mfg. process
Characteristics are static dimensions, shape factors, surface finishes or bulk material properties
Key doesn’t just mean it is important!
It means there is high risk because…
unproven – we lack facts, little or no data - we don’t know!
unstable & must be “watched”!
dependent on different Design or Supplier’s capabilities
Intro to KPD&M, Copyright 2010, PDSS Inc.

6. Key Parameters are like slippery bars of soap
Key Parameters are like slippery bars of soap! – risk of “getting out of hand”!
Risk!
Cannot afford to call everything that is merely important a Key Parameter
$$$
Intro to KPD&M, Copyright 2010, PDSS Inc.

7. The road to being designated Key…
1. Vary an X & measure the effect on Y…. DY/DX
2. Do so repeatedly & measure the variation around DY caused by each DXi = random error = e
3. Define the ratio between the Signal (DY/DXi) & the Noise e
… this is called the F Ratio = Strength of each DXi on DY when compared to random noise in the replicated data
4. Establish if each Xi’s effect on Y is statistically significant… calculate the p value
5. Establish the Capability Index for Ys & Xs… calculate the Cp & Cpk values for Y & X under nominal (Cp) & stressful (Cpk) conditions!
Intro to KPD&M, Copyright 2010, PDSS Inc.

8. Stability, F Ratio, p Value, Robustness, Tunability & Capability tell the Story!
If Xs & Ys are:
statistically significant…. Low p values (< 0.05)
have high F Ratios (>> 4) from Analysis of Variance (ANOVA)
possess unstable behavior (SPC trend & control issues)
have low Cp under nominal conditions… then they are extremely risky & are designated as Keys!
These are our highest priority Keys to work on.
If these same Xs & Ys
possess high sensitivity to stressful noises after Robust Design
difficult to tune onto the desired target after Robust Design
have low Cpk under stressful conditions… then they are still very risky & are designated as Keys!
Intro to KPD&M, Copyright 2010, PDSS Inc.

9. Key >>> NUD! Guilty until proven Innocent!
Key parameters are under suspicion – we don’t trust them!
measured & watched for drift in mean
measured & watched for changes in s
A parameter or characteristic can come off our list of Keys…. Re-designated as ECO!
Proven stability over time (SPC Charting)
Ease of control under nominal & stressful conditions (Robust & Tunable performance)
Sustained capability (Cp/Cpk) as cost is reduced
X & R Charts
Intro to KPD&M, Copyright 2010, PDSS Inc.

10. What is Key Parameter Development & Management?
A proactive process for:
Identifying
Connecting
Tracking
Refining
Preventing problems
Documenting a hierarchy of:
Key requirements & the integrated set of measured functions, specifications & set points
- down through a product architecture and its production & support processes.
Intro to KPD&MM, Copyright 2010 PDSS Inc.

11. …but not by rushing & cutting corners.
A bit of history….
From Dogma & Faith…
Dogma = Cheaper & Faster – We must Hurry!!!
Faith = We You will make it!
To Doubt & Experimentation…
Doubt = We have risk & uncertainty – we need facts!
Experimentation = We can & will take the time to learn! X
Learning generates facts which reduce uncertainty & lower risk…
…but not by rushing & cutting corners.
Intro to KPD&M, Copyright 2010, PDSS Inc.

12. Some personal history…
Dogma & Faith results circa compared to Doubt & Experimentation results from at Kodak…
A focused effort was implemented in Kodak’s digital printing business unit on the DigiMaster Project:
Our 1st ever Commercial Systems Engineering Org., Center of Excellence & SE Process
Comprehensive integration of Key Parameter Development & Mgt. approach into Phase-Gate PDP
Clear definition of “Key” Customer needs
Heavy emphasis on Reliability Development using Robust Design
Detailed “Design for X” focus on produceability & serviceability
Strong Project Manager, rigorous PM methods & dedicated, accountable PDT (functional Centers of Excellence supported it)
Intro to KPD&M, Copyright 2010, PDSS Inc.

13. The DigiMaster 9100 digital printing system
Over 10,000 parts
< 30 major subsystems (chemo-opto-mechatronics)
Req’d 6s image quality across 15 measurable attributes
Req’d 150K MIBSC within 95% Confidence Limits

14. Historic example of Prod. Dev
Historic example of Prod. Dev. Team performance before the use of SE & KP enabled work flow…
Pre-SE, KPD, DFSS, etc.
Targets
Change over to supplier mtl.s & parts
Independent SS Changes to improve System Performance
Late integration of tweeked SSs & purchased accessories
System integration too early…
MTBF
50-60% of Target
Gate 2
Gate 3
Gate 4
Gate 5
Time
Defining Lean in the Context of DFSS

15. Development Teams can improve results with SE, Key Parameter Development & select DFSS tools…
SE/KPD/DFSS Actual
+2s UCL
Pre-SE, KPD, DFSS, etc.
Target
>95% of Target
-2s LCL
MTBF
50-60% of Target
Gate 2
Gate 3
Gate 4
Gate 5
Time
Defining Lean in the Context of DFSS

16. Duane plot from an actual project
Defining Lean in the Context of DFSS

17. What made the difference?
Macro-effects
Created a formal systems engineering organization
- clear SE roles, with SE tools, tasks & deliverables tied to Gate Requirements measured with performance score cards – not checklists
Enhanced the SE team to actively use specific KP tasks with DFSS tools to complete the tasks,
directly assisting sub-teams – producing the right SE Gate deliverables
Micro-effects
Key Parameter Mgt.: clear definition of Key reqts. flow down & rigorous measurement of capability flow-up (Cp & Cpk trace-ability)
System Integration, system sensitivity analysis & reliability testing only AFTER subsystem & subassy. robustness optimization was completed
reliability development vs. assessment
Complete story is in Ch. 7:
Systems Architecting, Engineering & Integration using DFSS & Key Parameter Development
Defining Lean in the Context of DFSS

18. What does System Development look like as a flow of work over time?
The Super-set of System Engineering Macro- Functions:
Architecting
Engineering
Integration
Assessment & Validation
System Performance Balancing
Internal & External Needs
Subsystem Interface Development & Robustness Optimization
System Functions
System Modeling
System KPM Database Transfer to Production, Service & Tech. Support
System Integration & Stress Testing
System Internal & External Validation
System Architecture
System Reqts.
Flow of System Architecting, Engineering, Integration & Assessment Tasks
Defining Lean in the Context of DFSS

19. Process Map of Major System Architecting, Engineering, Integration & Assessment Tasks
Define System Reqts
Define System Functions
Define System Architecture
Partition System into Subsystems
Create & build KPM Database
Generate System FMEA
Lead System Integration Meetings
Develop System Noise Map
Balance Interface Sensitivities – create latitude
Define System Integration DOEs &Test Plans
Integrate System Test Rigs & Data Acq. System
Conduct System Integration Stress Tests
Balance System Performance
Conduct Reliability Assessments
Validate System Performance
Transfer KPM Database to Mfg. & Support
Defining Lean in the Context of DFSS

20. Key Parameter Management Process
Key Parameter Enabled Systems & Design Engineering: Key Parameter Dev. process & enabling DFSS tools
Concept
Design
Optimize
Verify
Key Parameter Management Process
Requirements Development Process
Full KPD&M details: Ch.s 8-13 of DFSS text
Concept Design Process
Sequential Design of Experiments Process
Reliability Definition, Modeling, Development & Assessment Process
Design for “X” Process
- Manufacturing, Assembly & Cost; Service Maint. & Support
- Environment, Health, Safety, Legal & Regulatory
Defining Lean in the Context of DFSS

21. Allocated Reqt.s Flow-down & Measured Capability Roll-up
VOC Needs
Customer Satisfaction
Verification &
Preventive / Contingent
Action
Process
Product Reqts.
Product CFR Cp & Cpk
Subsystem Reqts.
Subsystem CFR Cp & Cpk
Subassembly Reqts.
Subassembly CFR Cp & Cpk
Component Reqts.
Component Spec. Cp & Cpk
Flow down of the reqts to be fulfilled through the measurement of KFRs & KPs
Roll-up of Cp & Cpk through the measurement of KFRs & KPs
Mfg. Process Reqts.
Mfg. Process Cp & Cpk
Defining Lean in the Context of DFSS

22. Requirements Development Process
…Flow-down of NUD / Kano requirements to be fulfilled
VOC Needs
Enabling Tools. Methods & Best Practices:
Customer Interviewing
KJ Analysis
NUD Screening & Kano Analysis
QFD
Requirements Trace-ability & Documentation (DOORS, etc.)
Product Reqts.
Subsystem Reqts.
Subassembly Reqts.
Component Reqts.
Mfg. Process Reqts.
Defining Lean in the Context of DFSS

23. System Concept Design Process
Step 1: External Needs
Gathering, Processing & Validating the Voices of the Customer, Marketing, Technology & Business
Step 2: Internal Requirements & Constraints
Generating & documenting a system of NUD / Kano requirements in a Key Parameter Mgt. data base
Step 3: Innovation, Architecting & Solutions
Concept Generation, Feasibility Evaluations & final Concept Selection
Defining Lean in the Context of DFSS

24. Metrics for Requirements Can be Compared to Measures of Sample Data
What is Required?
Customer Level (USL – LSL)
System Level (USL – LSL)
Subsystem Level (USL – LSL)
Subassembly Level (USL – LSL)
Component Level (USL – LSL)
Mfg. Process Level (USL – LSL)
What is Measured?
Customer Level (Avg & σ)
System Level (Avg & σ)
Subsystem Level (Avg & σ)
Subassembly Level (Avg & σ)
Component Level (Avg & σ)
Mfg. Process Level (Avg & σ)
From this comparison we can document performance Capability
Intro to KPD&M, Copyright 2010, PDSS Inc.

25. Reqt. Allocation & KP Measuring down through the System to Subsystems, Sub Assemblies, Parts & Mfg. Processes!
Key Reqt.s Allocation & Linkage
Product or System Level
Sub System Level
Sub Assy Level
Part Level
Capability Assessment & Traceability
Mfg. Level
Intro to KPD&M, Copyright 2010, PDSS Inc.

26. Product Functional Capability
(USL-LSL): tolerance range for a KFR response within the product (Sys/SSys/SAys)
(USL-LSL): as stated in the Reqts. Document
6s = six times the sample std. dev of a Key Functional Response KFR in the design
“s” measures functional variation
“s” is composed of both mfg. and customer-base variation in product usage and environments
sKFR
Intro to KPD&M, Copyright 2010, PDSS Inc.

27. Part Specification Capability
(USL-LSL): tolerance range for a KTF spec. on a component / assembly
(USL-LSL): directly traceable to both Product & Manufacturing KFRs
6s = six times the sample std. dev of a KTF Part specification
“s” measures dimensional, surface finish, bulk material property or material variation
“s” is composed only of unit-to-unit Part variation
sKTF
Intro to KPD&M, Copyright 2010, PDSS Inc.

28. Manufacturing Process Capability
(USL-LSL): tolerance range for a KFR spec. on a production machine
(USL-LSL): directly traceable up to Part KTF Spec.
6s = six times the sample std. dev of a KFR specification
“s” measures Process functional variation
“s” is composed only of functional mfg. variation
sKFR
Intro to KPD&M, Copyright 2010, PDSS Inc.

29. Required KP Mgt. Data for any form of Capability Assessment
Gage R&R
All KFRs, KPs or KTF Spec.s must have a capable metrology process documented & in use
Each KFR, KP or KTF Spec. is placed under SPC so the Cp can be routinely quantified for Phase-by-Phase growth & Life Cycle stability characterization
All KFRs typically have a target of Cp = 2 & Cpk of 1.5
I & MR Chart
Capability Study
Intro to KPD&M, Copyright 2010, PDSS Inc.

30. KPD&M Flow-Down Map System Reqt. Y=System KFR Su bsystem Reqt.1
=SS
KFR
Subsystem Reqt. 2 3
Subsystem-to-System Level Transfer Functions Y = f(x1, x2, …xn)
Subassy. Reqt. X
=SAssy.
=SAssy .
Subassy-to-Subsystem Level Transfer Functions: Y = f(x1, x2, … xn)
Component Reqt.s n
=Comp.
KTF Spec.s
Mfg. Process Reqt.s
=Mfg..
NUD VOC Need #1
NUD VOC Need #2
Intro to KPD&M, Copyright 2010, PDSS Inc.

31. Modeling & Simulation
M&S was in place & was pretty good - but it left KP knowledge gaps - & not just a few!!!
Could not predict physics-based interactions between controllable engineering parameters very well…
Xi * Xj = ???
Could not predict physics-based interactions between controllable engineering parameters AND NOISE PARAMETERS = unwanted sources of variation…
Xi * Noise = ???
From variation in production parts, assembly & materials
From variation in disruptive sources external to the system
From variation in deteriorative sources internal to the system
Weibull, Exponential, Gamma, Rayliegh, Lognormal, Normal, etc.????
Intro to KPD&M, Copyright 2010, PDSS Inc.

32. 2 Major Matrices dominate the KP Dev. Process!
On the Requirements Side:
The Houses of Quality from NUD-based QFD
Translated, Ranked, Prioritized & Allocated Key Customer Needs
On the Parameters Side:
The Designed Experiment (DOE)
NUD Transfer Functions (Key Y = f(Xs)) measured, Ranked & Prioritized
Intro to KPD&M, Copyright 2010, PDSS Inc.

33. Sequential Designed Experiments Process
Concept
Design
Optimize
Verify
Tolerance Balancing DOEs
Multi-vari Studies
Screening DOEs
System Stress Test DOEs
Modeling DOEs
Robust Design DOEs
…Iterate…
Optimization DOEs
Building your knowledge of statistically significant Key Parameters using a sequential DOE strategy
Defining Lean in the Context of DFSS

34. DOE choices in Product Commercialization
There are 7 major types of Designed Experiments
1. Multi-vari studies
- (correlation & hypothesis forming studies)
2. Screening Experiments
- (sorting controllable factors & noise factors for significance)
3. Modeling Experiments
- (quantifying Y = f(x) relationships)
4. Mean Optimization Experiments
- (adjust mean performance to hit a desired target)
5. Robustness-to-Noise Experiments
- (reduce s in the presence of noise)
6. System Stress Testing Experiments
- (identify sensitivity across interfaces & system boundaries)
7. Tolerance Balancing Experiments
- (refine cost vs. quality in subsystems, subassemblies & parts)
“Everything should be as simple as possible – but not simpler…”
Defining Lean in the Context of DFSS

35. Key Functional Response Key Adjustment Parameter (KAP)
Identifying Key Functional Response & Key Adjustment Parameter Relationships
Key Functional Response
(KFR)
Ideal
Key Adjustment Parameter (KAP)
Intro to KPD&M, Copyright 2010, PDSS Inc.

36. Robust against Variation Mean Adjusted to VOC Target
Key Functional Robustness Parameters: KAPs & KFRPs: How they affect a KFR - Robust & Tunable Performance!
KFRPs are KFR Variance Reducers
KAPs are KFR Mean Shifters
Robust against Variation
Mean Adjusted to VOC Target
Intro to KPD&M, Copyright 2010, PDSS Inc.

37. Reliability Development Process
Concept
Design
Optimize
Verify
Reliability Requirements Definition
-System
-Subsystem / Subassembly
- Component
Reliability Modeling – Probabilistic Simulations
Reliability Development Tasks
- FMEAs, CAE/CARD, DOE, Robust Design, Tolerance Design
Reliability Assessment Tasks
Life Tests, Accelerated Life Tests
HALT, HASS, HAST, Destructive Tests
Defining Lean in the Context of DFSS

38. Design for “X” Process Concept Design Optimize Verify DfX Requirements
-System (Product & Production Processes)
-Subsystem / Subassembly
- Component / Materials
Design for X Tasks
- Benchmarking, DFMA, Design for Cost, VA/VE…
DfX Assessment Tasks
HSER DOEs & Related Tests
Defining Lean in the Context of DFSS

39. KPD enhanced Team Performance Score Cards
Preventive Peer Reviews
Contingent Design Reviews
Reactive Gate Reviews
Measuring the use of tools, completion of tasks and the fulfillment of Gate Deliverable requirements…
Defining Lean in the Context of DFSS

40. Gate Deliverable Scoring linkage from Tool & Task Scorecards
Tool Scoring Items
Quality of Tool Use
Data Integrity
Tool Results vs. Task Reqts
Task Scoring Items
Avg. Tool Score
% Task Fulfillment
Task Results vs. Gate Reqts
Gate Deliverable Scoring Items
Risk Accrual against Gate Reqts.
Confidence in Data Score
Defining Lean in the Context of DFSS

41. Summary – building KP Dev. capability & maturity
Companies who have deployed KPD&M are slowly realizing they can’t use it right if they don’t have SE functional excellence & governance in their Phase-Gate process…
With KPD&M integrated into SE the results are much better
Ad hoc systems work in product commercialization processes keeps you from being great…
SE capability maturity
KP enhanced SE Process, Roles, tool-task-deliverables…
Formal SE Process & Roles
Ad hoc SE
Defining Lean in the Context of DFSS

42. The ARDEC Story: Defining a process for Pro-active KPD&M
What approaches are available for conducting KP Development & Management?
Are the steps during Development different from those conducted when defining KPs after Launch?
Technology & Product Development?
Post-launch Production & Ongoing Life cycle Management out to Discontinuance?
Intro to KPD&M, Copyright 2010, PDSS Inc.

43. A New Technology & Product Development Process was constructed: Vector
Similar to the definition of a Vector, the ARDEC T&PDP will serve as a course or compass direction for navigating ARDEC IPTs through technology and product development projects doing the right things at the right time.
Webster - Vector: a quantity that has magnitude and direction and that is commonly represented by a directed line segment whose length represents the magnitude and whose orientation in space represents the direction; b: a course or compass direction c: a course to be taken by an aircraft.
ARDEC ‘s Technology & Product Development Process (T&PDP) = Vector
Intro to KPD&M, Copyright 2010, PDSS Inc.

44. Foundations of Vector Ford
Vector is built upon a wide variety of benchmarks that were “value-mined”…
8 major Corporations:
6 texts from product development consulting firms:
NASA / DoD TRL models
Latest version of the DoD
Ford
Intro to KPD&M, Copyright 2010, PDSS Inc.

45. Best elements integrated to design the T&PDP process….
Benchmarks
VOC
NUD Reqts.
Benchmarks, Hybridization and Pugh Concept Selection Process used to document Value Selection - led to the design of Vector Block Diagrams
Intro to KPD&M, Copyright 2010, PDSS Inc.

46. Block Diagrams: Defining What to do….
1. Entrance Criteria
Readiness
3. Major Activities
Tasks
Results
5. Deliverables
Completeness
6. Exit Criteria
Intent
2. Objectives
Enablers
4. Enabling Best Practices
Intro to KPD&M, Copyright 2010, PDSS Inc.

47. And when to do it….
The Vector Process is constructed of Blocks of Major Activities..
Block of Major Activities
Vector Technology Dev. Process…
9 Blocks of Major Activity Groups defined & documented:
TD1
TD2
TD3
TD4
TD5
TD6
TD7
TD8
TD9
Vector EMD Process…
10 Blocks of Major Activity Groups defined & documented:
EMD1
EMD2
EMD3
EMD4
EMD5
EMD6
EMD7
EMD8
EMD9
EMD10
Intro to KPD&M, Copyright 2010, PDSS Inc.

48. Including linkage between the Actions & their enabling Tool sets.
Each Block contains a designed Work Flow… adaptable to the type of Project
Block of Major Activities
Block of Major Activities
Activity 1
Activity 2
Activity 4
Activity 5
Activity 3
Activity 6
Block of Major Activities
Activity 1
Activity 2
Activity 4
Activity 5
Activity 3
Activity 6
Block of Major Activities
Activity 1
Activity 2
Activity 4
Activity 5
Activity 3
Activity 6
Block of Major Activities
Activity 1
Activity 2
Activity 4
Activity 5
Activity 3
Activity 6
Activity 1
Activity 2
Activity 4
Activity 5
Activity 3
Activity 6
MS Project Network Diagrams will illustrate serial / parallel flow paths of Major Activities within each Block…
Including linkage between the Actions & their enabling Tool sets.
Intro to KPD&M, Copyright 2010, PDSS Inc.

49. Aligning the Blocks to TRLs & MRLs – Vector added KP depth-of -rigor & clarity of the TRL / MRL definitions & detailed deliverables
TD3-4
TD5-6
TD 7
TD 8
EMD 10
TD3-4
TD5
TD6-7
TD 8
EMD 9
EMD 10
EMD 10
Intro to KPD&M, Copyright 2010, PDSS Inc.

50. Technology Dev. Phases & Gates were defined from the 9 TD Block Diagrams….
Phase 1: Technology Project Plan & Requirements Dev.
Phase 2: Technology Concept Dev.
Tech Dev. Project Definition & Plan 1
Tech Reqts Dev 2
Tech Concept Dev 3
Tech Functional & Analytical M&S 4
Phase 3: Technology Sub-level Dev. & Optimization
Phase 4: Technology Integration & Final Optimization
Subsys Tech Prototype & measmnt System Design & Dev 5
Tech Prototype perf Stability & Tunability Dev 6
Tech Robustness Dev (Dynamic) 7
Tech System Integration, Nominal & Stress Testing 8
Tech Transfer 9
Intro to KPD&M, Copyright 2010, PDSS Inc.

51. Product Dev. Phases & Gates were defined from the 10 EMD Block Diagrams….
Phase 1: Product Project Plan & Requirements Dev.
Phase 2: Product Concept Development
EMD Program definition and plan 1
Technical reqmnts Definition, documentation, and prioritization 2
Product & production process Concept development and selection, system architecture 3
Preliminary Subsys concepts, modeling, simulations, virtual designs 4
Subsys design and prototyping, test planning and measmnt systems capability readiness 5
Phase 3: Product Sub-level Dev. & Optimization
Phase 5: Product & Mfg. Process Verification & Validation
Subsys design testing and capability perf characterization 6
Subsys design robustness testing, optimization, DOEs under stress 7
System Integration, nominal & stress testing, desensitization 8
Final Product Design 9
Product design verification / Mfg Process verification and validation 10
Phase 4: Product System Integration & Optimization
Intro to KPD&M, Copyright 2010, PDSS Inc.

52. Example of Vector Technology Development Process Swim lanes loaded with major KPD&M Tasks
Intro to KPD&M, Copyright 2010, PDSS Inc.

53. Enabling Tools & Methods
11 General Steps in KPD after you are in Production – if you did NOT do KPD during Technology or Product Development…
KPD&M Process Step
Enabling Tools & Methods
Project Planning & Mgt., Monte Carlo Sim., Cost Estimation, SMART reqts. & goal ID, Intro to KPD&M Module
Step 1: Create a KPD&M Project Charter
Specific, in-depth experience; Technical expertise & judgment, DFLSS training, JIT training & mentoring in KP tool sets
Step 2: Create a cross-functional team of experts to help ID a thorough set of KPs
Customer/Stakeholder ID, Interviewing Methods, KJ Analysis, NUD vs. ECO classification, Kano Analysis, QFD & HOQs, Doors, Relational data base
Step 3: Generate / Assess requirement clarity, classification & flow-down
I-O-C Diagramming, P-Diagm’g, Noise Diagm’g, System Noise Mapping, Boundary & Interface Diagm’g, 1st Principles Modeling & Simulation
Step 4: Generate I-O-C-Diagrams, P-Diagrams, Noise & Boundary Diagrams
Functional Diagm’g, Flow Diagm’g, Cockpit SW, KP Data base dev., KP Scorecards, KP Reqts. & Measured Y worksheets
Step 5: Structure a Key Parameter Flow-down Tree & Relational Data base
NUD vs. ECO classification, Kano Analysis, Pareto process, QFD ranking, Function Trees & Flow Diagm’g., Noise Diagm’g, FMEAs
Step 6: ID unique sub-areas of focus; lean out, rank & prioritize the areas to work on
Measurement Systems Analysis, Gage R&R Studies
Step 7: Prove measurement systems are capable
Hypothesis formation, SPC & Cp/Cpk studies, DOEs, t-Tests, ALT, HALT, HAST, Duane Plotting
Step 8: Design & conduct experiments on candidate Key Parameters & Noises
ANOVA, Descriptive & Inferential Statistical methods, Regression Analysis, Correlation Analysis, Confidence Intervals, Main effects & interaction plotting
Step 9: Analyze data using ANOVA & other statistical methods to ID sensitivities & Cpk
Screening DOEs, ANOVA, Taguchi’s Loss Function, Additive Variance Modeling, SPC & Cp/Cpk Studies, F Ratios
Step 10: Establish & verify tolerance ranges & % contribution to variation of Key Ys
Control Planning, SPC & Cp/Cpk Studies, KP documentation, KP relational data base & Score cards
Step 11: Create a Mfg. & Production implementation & control plan for KPs

54. Summary of KPD&M Concepts
REQUIREMENT FLOW-DOWN & ALLOCATION
CAPABILITY FLOW-UP of Cp & Cpk
SYSTEM REQUIREMENTS
SYSTEM KFR PERFORMANCE
TRANSFER FUNCTION LINKAGE IS USED TO TRACK KEY RELATIONSIPS & TRANSMISSION OF VARIATION….
SUBSYSTEM REQUIREMENTS
SUBSYSTEM KFR PERFORMANCE
SUBASSEMBLY REQUIREMENTS
SUBASSY. KFR PERFORMANCE
COMPONENT REQUIREMENTS
COMPONENT KTF PERFORMANCE
MFG. PROCESS REQUIREMENTS
MFG. PROCESS KFR PERFORMANCE
Why do we take the time to do it properly? Problem Prevention.
Intro to KPD&M, Copyright 2010, PDSS Inc.