1.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 1 Chapter 7 Quality and Innovation in Product and Process Design

2.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 2 Strategic Quality Planning Quality and Innovation in Product and Process Design Chapter 7  Designing products for quality  The Design Process  Quality function deployment (QFD)  Technology in design  Prototyping methodologies  Designing for reliability  Environmental considerations in design

3.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 3 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing products for quality  What are the functions the customer wants?  What are the capabilities of the current product?  What are the limitations of the material we have selected?  Are there better materials available?  How much will the product cost to make?  How much must the product cost to make it successful in the marketplace?

4.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 4 Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Product idea generation Internal and external sources brainstorm new concepts.

5.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 5 Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Product idea generation Internal Sources:  Marketing  Management  Research and development  Employee Suggestions

6.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 6 Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Product idea generation External Sources:  The Customer

7.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 7 Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Technology selection  Technology feasibility statement  Technology development for process selection  Final product definition  Product marketing and distribution perpetration  Product design and evaluation  Manufacturing system design  Product manufacture, delivery and use

8.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 8 Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) The House of Quality A means for implementing customer needs into functional design

9.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 9 Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step:  Develop a list of customer requirements  Develop a listing if technical design elements  Demonstrate the relationship between the customer requirements and technical design elements

10.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 10 Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step:  Identify the correlation between design elements  Perform a competitive assessment of the customer requirements.

11.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 11 Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step:  Prioritize customer requirements  Prioritize technical requirements  Final Valuation

12.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 12 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design Designers tools: A square A pencil A drafting Table

13.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 13 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design Designers tools: A square A pencil A drafting Table Replaced by -----

14.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 14 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Computer Aided Design

15.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 15 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Computer Aided Design And Multi-user CAD Systems

16.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 16 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Computer Aided Design And Multi-user CAD Systems Hundreds of designers on the system simultaneously

17.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 17 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Geometric Modeling Engineering analysis Interface checking

18.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 18 Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD/CAM Computer Aided Design Computer Aided Manufacturing

19.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 19 Strategic Quality Planning Quality and Innovation in Product and Process Design Prototyping Methodologies Prototyping An iterative approach to design in which a series of product mockups are developed until the costumer and designer agree on the final design

20.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 20 Strategic Quality Planning Quality and Innovation in Product and Process Design Prototyping Methodologies Basic Prototype Non-working mockup of a product

21.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 21 Strategic Quality Planning Quality and Innovation in Product and Process Design Prototyping Methodologies Paper Prototype A series of drawings developed … on CAD

22.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 22 Strategic Quality Planning Quality and Innovation in Product and Process Design Prototyping Methodologies Working Prototype Fully working models of the final product

23.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 23 Strategic Quality Planning Quality and Innovation in Product and Process Design Prototyping Methodologies  Organizing the Design Team  Product Life Cycle / Product families  Complementary products  Designing products that work  Design for the manufacturing method  Design for maintainability

24.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 24 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Failure Modes and Effects Analysis (FMEA ) 1. Improvement of safety, quality and reliability 2. Improvement of a companies image 3. Increased user satisfaction 4. Reduction in product development cost 5. Record of actions taken

25.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 25 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Where FMEA can be applied 1. Concept 2. Process 3. Design 4. Service 5. Equipment

26.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 26 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  How FMEA works 1. Give each component in the system a unique qualifier 2. List all functions each part of the system performs 3. List the one or two failure modes for each function

27.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 27 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  How FMEA works 4. Describe what effect each failure mode of the component will have. 5. Determine whether the failure will result in a hazard 6. Estimate the relative likelihood of occurrence for each failure in a 10 point scale

28.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 28 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  How FMEA works 7. Estimate the ease with which the failure may be detected 8. Use the estimates from steps 5,6 and 7 to identify the highest risks 9. Decide what action will be taken to eliminate or reduce the likelihood…

29.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 29 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Fault Tree Analysis An analytic tool which graphically renders the combination of faults that lead to the failure of a system

30.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 30 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Failure Modes, Effects and Criticality Analysis (FMECA) 1. A description of the products functions 2. Listings of the potential failure modes 3. Potential effects each failure mode could have 4. Potential causes of each failure mode

31.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 31 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Failure Modes, Effects and Criticality Analysis (FMECA) 5. Preventive measures 6. Ranking of each preventive measure 7. Ranking of the difficulty of detection 8. An estimate of the probability that a cause of a potential failure will be detected and corrected.

32.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 32 Strategic Quality Planning Quality and Innovation in Product and Process Design Designing for Reliability Reliability Analysis Tools  Product Traceability and Recall Procedures Unforeseen defects will occur.  Product traceability  Recall procedures  Trace products with a minimum of cost

33.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 33 Strategic Quality Planning Quality and Innovation in Product and Process Design Environmental Considerations in Design Green Manufacturing  Design for reuse  Design for disassembly  Design for remanufacture

34.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 34 Strategic Quality Planning Quality and Innovation in Product and Process Design Summary As life cycles for products become shorter a focus on quality is necessary to remain competitive

35.  Copyright © 2010 Pearson Education, Inc. Publishing as Prentice Hall. 7- 35 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Printed in the United States of America.