Presentation on theme: "Chapter 12- Quality By Design"— Presentation transcript:
1 Chapter 12- Quality By Design IntroductionConcurrent EngineeringLife-Cycle Costs and Engineering ChangesQuality Function DeploymentDesign for Manufacture and AssemblyTaguchi MethodsConclusion
2 Metrics for Design Quality Percent of revenue from new products or servicesPercent of products capturing 50% or more of the marketPercent of process initiatives yielding a 50% or more improvement in effectivenessPercent of suppliers engaged in collaborative design
3 Concurrent Engineering The Design ProcessLife-Cycle Costs and Engineering ChangesWhat Concurrent Engineering Teams DoBenefits of Concurrent EngineeringConcurrent Engineering Team Organization
4 What Concurrent Engineering Teams Do Determine the overall character of the product, its design, and method of manufacture.Perform product functional analysis.Explore ways to improve producibility and usability.Design a process for product assembly and production control, and design the parts of the product to be compatible with the assembly process.Design the manufacturing processes for the product.
5 Benefits of Concurrent Engineering Helps to understand the requirements of customers so that a better product acceptable to customers may be designed and made.Product development time is reduced since design and process planning activities are completed simultaneously.Design trade-offs, for example, between product features and production capabilities can be easily be facilitated with a view to improve the design.
6 Life-Cycle Costs and Engineering Changes - Costs incurred from cradle to grave- About 80% of product costs are committed in the design and development phase of a product.- Consequently, it is important to avoid mistakes early on in the design process.- The design and redesign process will require numerous engineering change orders that could be time consuming and lengthy.-
8 FMEA for Potato Chips Stale FAILUREMODE CAUSE OF FAILURE EFFECT OF FAILURE CORRECTIVE ACTIONStaleLow moisture content, expired shelf life, poor packagingTastes bad, won’t crunch, thrown out, lost salesAdd m cure longer, better package seal, shorter shelf lifeBrokenToo thin, too brittle, rough handling, rough use, poor packagingCan’t dip, poor display, injures mouth, chocking, perceived as old, lost salesChange recipe, change process, change packagingToo SaltyOutdated receipt, process not in control, uneven distribution of saltEat less, drink more, health hazard, lost salesExperiment with recipe, experiment with process, introduce low salt version
9 Value Analysis (Value Engineering) Ratio of value / costAssessment of value :1. Can we do without it?2. Does it do more than is required?3. Does it cost more than it is worth?4. Can something else do a better job5. Can it be made by less costly method, tools, material?6. Can it be made cheaper, better or faster by someone else?
10 Design for Environment Design from recycled materialUse materials which can be recycledDesign for ease of repairMinimize packagingMinimize material & energy used during manufacture, consumption & disposal
12 Quality Function Deployment (QFD) Developed by Mitsubishi’s Kobe Shipyard in 1972 and was adopted by Toyota 1978QFD is being used by numerous US companies now- This is a planning, communication, and documentation technique used to resolve design problems- Translates the “voice of the customer” into technical design requirements- Displays requirements in matrix diagrams- First matrix called “house of quality”- Series of connected houses
13 Design characteristics Customer requirements Competitive assessment House of QualityCorrelation matrixDesign characteristicsCustomer requirementsTarget valuesRelationship matrixCompetitive assessmentImportance123456
14 Competitive Assessment House of QualityFigure 3.8Irons wellEasy and safe to useCompetitive AssessmentCustomer RequirementsPresses quickly 9 B A XRemoves wrinkles 8 AB XDoesn’t stick to fabric 6 X BAProvides enough steam AB XDoesn’t spot fabric 6 X ABDoesn’t scorch fabric 9 A XBHeats quickly 6 X B AAutomatic shut-off ABXQuick cool-down 3 X A BDoesn’t break when dropped 5 AB XDoesn’t burn when touched 5 AB XNot too heavy 8 X A B
15 House of Quality Customer Requirements Presses quickly - - + + + - Time required to reach 450º FTime to go from 450º to 100ºProtective cover for soleplateMaterial used in soleplateFlow of water from holesEnergy needed to pressThickness of soleplateAutomatic shutoffSize of soleplateNumber of holesWeight of ironSize of holesCustomer RequirementsPresses quicklyRemoves wrinklesDoesn’t stick to fabricProvides enough steamDoesn’t spot fabricDoesn’t scorch fabricHeats quicklyAutomatic shut-offQuick cool-downDoesn’t break when droppedDoesn’t burn when touchedNot too heavyIrons wellEasy and safe to use
16 House of Quality + - Figure 3.10 Protective cover for soleplate Time to go from 450º to 100ºTime required to reach 450ºMaterial used in soleplateFlow of water from holesEnergy needed to pressThickness of soleplateAutomatic shutoffSize of soleplateNumber of holesWeight of ironSize of holes-+
17 Design For Manufacturing and Assembly Design AxiomsDFM Guide LinesDFA PrinciplesFully Exploiting DFMA
18 Taguchi Methods Robust Design Taguchi Approach to Design Planned ExperimentationDesign of ExperimentsDOE and DFMA for Process ImprovementOrthogonal ArraysQuality LossCriticism of Taguchi