Wnter Product Quality and Robust Design

Wnter What is your definition of a Quality Product? Is there a difference between Quality and Manufacturability? What are some of the “quality” concerns about your senior project? How does product quality tie back into Functional Specs? How are you going to validate your critical design specs?

Wnter Why is Product Quality Important? There is only one excuse not to invest time in improving your Product Development process: any competition customers must continue purchasing your good(s) continue to make adequate profit You do not have now and will never have any competition (i.e., you are in a permanent monopoly situation), and your customers must, out of necessity for all time, continue purchasing your good(s) or service(s) in sufficient quantity that your company can continue to make adequate profit even in the face of cost inflation.

Wnter How Do You Select Among Competing Suppliers? 1. Customer buys on value 2. Value = Quality relative to Price 3. Quality includes all non-price attributes 4 Product 4 Customer service 4. Quality, Price and Value are relative Value Quality Price Product Customer service

Wnter How Successful is an Average Launch? 1 Successful Product PDMA New Product Development Survey: Performance and Best Practices. Chicago; 1991 Screening and Evaluation Business Analysis Development Testing Commercialization For every 11 serious ideas…… 3 enter development, 1.3 are launched, and 1 succeeds

Wnter Where do the Winners Invest Their Time?

Wnter Quality Lever 1000:1 PRODUCT DEFINITION 100:1 PRODUCT DESIGN 10:1 PROCESS DESIGN 1:1 PRODUCTION PRODUCT IMPROVEMENT LOW VISIBILITY HIGH RETURNS HIGH VISIBILITY LOW RETURNS When do you add Quality in the Design Process?

Wnter In the last 50 years, there has been a dramatic improvement in product quality. Before that time, much of product quality was in the ease of repair. Examples? How many TV Repairs shops exist now vs. 1960? How many auto-mechanics shops now exist? How many of you have ever had a wrist watch repaired? What has changed? How do insure your product has high quality?

Wnter Total Defects/Unit E s c a p i n g D e f e c t s No matter how good your inspection and test processes are, the more defects you create, the more defects escape to the customer You can try and inspect for quality

Wnter The Inspection Exercise Count the number of times the 6th letter of the alphabet appears in the following text. You have 45 Seconds to complete your inspection. The necessity of training farm hands for the first class farms in the fatherly handling of farm live stock is foremost in the eyes of the farm owners. Since the forefathers of the farm owners trained the farm hands for first class farms in the fatherly handling of farm live stock, the farm owners felt they should carry on with the family tradition of training farm hands of the first class farmers in the fatherly handling of farm live stock because they believe it is the basis of good fundamental farm management.

Wnter What is your answer? 36 What does this tell you about trying to inspect in quality?

Wnter The Inspection Exercise The necessity of training farm hands for the first class farms in the fatherly handling of farm live stock is foremost in the eyes of the farm owners. Since the forefathers of the farm owners trained the farm hands for first class farms in the fatherly handling of farm live stock, the farm owners felt they should carry on with the family tradition of training farm hands of the first class farmers in the fatherly handling of farm live stock because they believe it is the basis of good fundamental farm management.

Wnter The effect of designed-in quality 2308, ,807 46,  PPM Process Capability Defects per Million Opp.

Wnter A 3   Process means that you will have 93.6% good units coming out of the process. That sounds pretty good until you think about the consequences of the failures. What types of products can be successful with 95% quality? What products require higher quality? Would you ride on an airplane that had 95% quality?

Wnter What Causes Defects? Excess variation due to: Manufacturing processes and measurement systems Supplied material variation Unreasonably tight specifications (tighter than the customer requires for a robust design) Inadequate Design Margin Unstable Parts and Materials Insufficient Process Capability

Wnter Dissecting Design Process Capability LSLUSL Poor Support of Robust Product Functionality Process Capability Design Overly Sensitive to “Noise” Inadequate Functional Capability Supplied Material Variation Inadequate Measurement Capability Way off Target Out of Spec.

Wnter A Three Sigma Process Upper Spec Lower Spec 33 33 Process Spread Tolerance

Wnter A Six Sigma Process 3 66 Lower SpecUpper Spec Process Spread Tolerance

Wnter Ford (Batavia Plant)  Produced Ford-Designed Transaxle  Built in Batavia, OH and in Japan (Mazda)  Both met engineering specifications but……  Fleet owners stated that some Escorts shifted smoothly while others were not so good (based on small sample size).  Analysis:  All “Smooth” shifting Transaxles were built in Japan  Both met specs, but…….

Wnter Batavia

Wnter Mazda - Japan

Wnter Vin Vout V+ 100 Ώ 1K Ώ 100 Ώ What is the Gain of this circuit? Robust Design How do components effect your design?

Wnter Robust Design What about Resistor tolerances? If you specify 10% resistors what range of gain should you expect to see?.9K 100 > /.09 = 12.2 : 12.2 * 12.2 = / 110 = 8.18 ; 8.18 x 8.18 = 66.9 Therefore your gain could vary from 66.9 – 150; 2.24 to 1 How would you reduce the process variation?

Wnter How do you improve Quality? The Design The Components The Process It is difficult to test-in Quality. It is also very expensive. What do you do with failed units? It usually costs at least twice as much to repair failed units. Why is this true? What are some of the things you are going in your designs to make them more robust?

Wnter Homework assignment Develop a test plan for at least one of the critical specifications of your senior project. Describe why you chose these specs. Describe the test, including test equipment involved, measurement technique, and expected results. This plan should also be included in the final report with actual numbers from the test process. Due next Tuesday, Mar. 3rd. Get your website or alternate team management site up to date, so that I can review it next week. Each team leader needs to send me a valid URL and password if required to get on your site. Send me the URL information by end of day on Friday.

Wnter Discussion topic for next lecture— me with answer Vote as a team on the following: 1. Which would you choose? A sure $100, or a coin flip for $200 or nothing. 2. Which would you now choose? A sure loss of $100, or a coin flip for a loss of $200 or $0? 3. What is the difference in the two scenarios?