1. Training Presentation on Design Control Ryan McLaughlin OISM 470W

2. Design Control What Will Be Covered Definition of Design ControlDefinition of Design Control Technology In DesignTechnology In Design Taguchi MethodTaguchi Method BenchmarkingBenchmarking QS 9000QS 9000 SummarySummary

3. Definition of Design Control Design Control – “A set of steps focused on managing the design of a product.”

4. Brainstorming Exercise Think of how much money your organization spends on error correction each year. Implementing a Design Control system can cut long term costs as well as improve quality and eliminate waste.

5. Technology In Design In today’s changing world, technologies like Computer Aided Design (CAD) have emerged as the standard tool in designing new products.

6. Brief Overview of CAD Can be used to simulate real- world situations.Can be used to simulate real- world situations. Multi-User CAD systemsMulti-User CAD systems Design ReviewDesign Review Computer Aided Inspection (CAI)Computer Aided Inspection (CAI) Computer Aided Testing (CAT)Computer Aided Testing (CAT)

7. Why Implement a CAD System? Reduce costsReduce costs Improve Accuracy of DesignImprove Accuracy of Design Improve Accuracy of TestingImprove Accuracy of Testing Overall Improvement in QualityOverall Improvement in Quality

8. The Taguchi Method The Taguchi Method for quality improvement is named after Dr. Genichi Taguchi who first introduced the method at AT&T Bell Laboratories in 1980.

9. The Taguchi Method The Taguchi Definition of Quality differs from traditional definitions of qualitydiffers from traditional definitions of quality Taguchi said Ideal Quality is delivered when “a product or service performs its intended function throughout its projected life under reasonable operating conditions without harmful side effects.”Taguchi said Ideal Quality is delivered when “a product or service performs its intended function throughout its projected life under reasonable operating conditions without harmful side effects.”

10. The Taguchi Method Robust DesignRobust Design products should be designed so that they are free of all defects and are of the highest quality.

11. Robust Design (The Taguchi Method) Three Step Method for Creating Robust Designs Concept DesignConcept Design Parameter DesignParameter Design Tolerance DesignTolerance Design

12. Concept Design Deals with the design of the process.Deals with the design of the process. Properly selecting process components and methods can reduce costs and increase the quality of the finished product.Properly selecting process components and methods can reduce costs and increase the quality of the finished product.

13. Parameter Design Deals with finding the optimal levels of variables that management can control in a process.Deals with finding the optimal levels of variables that management can control in a process. Parameter design does not usually affect production costs, but rather attempts to find the best level of performance for the system.Parameter design does not usually affect production costs, but rather attempts to find the best level of performance for the system.

14. Tolerance Design Refers to finding the acceptable variation limits after the parameter design has been established.Refers to finding the acceptable variation limits after the parameter design has been established. Usually results in an increase in production costs, but also an increase in production quality.Usually results in an increase in production costs, but also an increase in production quality.

15. Robust Design Steps In order to create a robust design, the following steps are used to incorporate the three perspectives Taguchi states.

16. Steps for Creating a Robust Design 1. Identify the main Function 2. Identify the noise factors and testing conditions 3. Identify the quality characteristics to be observed and the objective function to be optimized 4. Identify the control factors and their alternative levels 5. Design the matrix experiment and define the data analysis procedure 6. Conduct the matrix experiment 7. Analyze the data and determine near optimum levels for the control factors 8. Predict the performance at these levels

17. Benchmarking Another method that can be helpful in creating high quality designs is benchmarking. A benchmark is a company which is recognized for being the best in a certain field.

18. Benchmarking Companies model themselves after the benchmark corporations in their specific field.Companies model themselves after the benchmark corporations in their specific field. The initiator firm might contact the target firm for information and statistics to be used for improvement of both corporations.The initiator firm might contact the target firm for information and statistics to be used for improvement of both corporations.

19. Benchmarking There are six types of benchmarking. Process BenchmarkingProcess Benchmarking Financial BenchmarkingFinancial Benchmarking Performance BenchmarkingPerformance Benchmarking Product BenchmarkingProduct Benchmarking Strategic BenchmarkingStrategic Benchmarking Functional BenchmarkingFunctional Benchmarking

20. QS 9000 QS9000 is a supplier development programQS9000 is a supplier development program Provides a supplier standard for auto companiesProvides a supplier standard for auto companies QS9000 has a requirement dealing with design controlQS9000 has a requirement dealing with design control

21. QS 9000 The Design Control Requirement of QS9000. Suppliers must be qualified in value engineering, geometric tolerance and dimensioning, and the Taguchi Method.Suppliers must be qualified in value engineering, geometric tolerance and dimensioning, and the Taguchi Method.

22. QS9000 – A Real World Example A team of representatives from GM, Ford and Chrysler developed the QS9000 standard, including the standard for design control.A team of representatives from GM, Ford and Chrysler developed the QS9000 standard, including the standard for design control. Suppliers to these auto manufactures need to be QS9000 certified.Suppliers to these auto manufactures need to be QS9000 certified.

23. Exercise Write down the approximate annual cost of error correction and losses due to poor quality in your organization.Write down the approximate annual cost of error correction and losses due to poor quality in your organization. Now calculate approximately how much a design control system such as CAD would cost to implement. A QMS/ISO9000 Design control system can cost between $10,000 and $500,000, depending on the size of the corporation.Now calculate approximately how much a design control system such as CAD would cost to implement. A QMS/ISO9000 Design control system can cost between $10,000 and $500,000, depending on the size of the corporation. Consider that it could be free to employ the Taguchi Method and also improve quality and cut costs.Consider that it could be free to employ the Taguchi Method and also improve quality and cut costs.

24. Summary Design Controls can help improve quality and cut costs.Design Controls can help improve quality and cut costs. Free ideas like the Taguchi Method are harder to implement but can pay off in the end.Free ideas like the Taguchi Method are harder to implement but can pay off in the end. Technology like CAD systems can also aid in design qualityTechnology like CAD systems can also aid in design quality

25. Bibliography http://mijuno.larc.nasa.gov/pap/robdes/robdes.html “DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN APPROACH.” By Resit Unal and Edwin B. Deanhttp://mijuno.larc.nasa.gov/pap/robdes/robdes.html “DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN APPROACH.” By Resit Unal and Edwin B. Deanhttp://mijuno.larc.nasa.gov/pap/robdes/robdes.html “Managing Quality, An Integrative Approach” By S. Thomas Foster“Managing Quality, An Integrative Approach” By S. Thomas Foster “Plant and Service Tours in Operations Management” by Roger W. Schmenner“Plant and Service Tours in Operations Management” by Roger W. Schmenner http://manufacturing.software-directory.com/software- 2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Contr ol.ISO.9000.44.shtml QMS PROGRAMS /ISO 9000 DESIGN CONTROL (ISO 9000/4.4)http://manufacturing.software-directory.com/software- 2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Contr ol.ISO.9000.44.shtml QMS PROGRAMS /ISO 9000 DESIGN CONTROL (ISO 9000/4.4)http://manufacturing.software-directory.com/software- 2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Contr ol.ISO.9000.44.shtmlhttp://manufacturing.software-directory.com/software- 2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Contr ol.ISO.9000.44.shtml