Chapter 7 Quality and Innovation in Product and

Chapter 7 Quality and Innovation in Product and Process Design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 1

Strategic Quality Planning Quality and Innovation in Product and Process Design Chapter 7 ØDesigning Products for Quality ØThe Design Process ØQuality Function Deployment (QFD) ØTechnology in Design ØOther Design Methodologies ØDesigning for Reliability ØProduct Traceability and Recall Procedures ØEnvironmental Considerations in Design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 2

Strategic Quality Planning Quality and Innovation in Product and Process Designing Products for Quality ØWhat are the functions the customer wants? ØWhat are the capabilities of current products? ØWhat are the limitations of the materials we have selected for the product? ØAre there better materials available? ØHow much will the product cost to make? ØHow much must the product cost to make it successful in the marketplace? Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 3

Strategic Quality Planning Quality and Innovation in Product and Process Designing Products for Quality Kano Quality/Design Model Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 4

Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Generic Product Design Process Copyright © 2013 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 Step 1 of the Product Design Process Internal and external sources brainstorm new concepts. Copyright © 2013 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 Internal Sources: ØMarketing ØManagement ØResearch and development ØEmployee Suggestions Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. Altair 8800 Computer 7 - 7

Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Product idea generation External Sources: ØThe Customer ØIndustry Experts ØConsultants ØCompetitors ØSuppliers ØInventors Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 8

Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Customer Future Needs Projection Step 2 of the Product Design Process Predicting future customer needs Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 9

Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process Technology selection for product development ØStep 3 of the Product Design Process ØTechnology feasibility statement ØAssesses a variety of issues ØNecessary parameters for performance ØManufacturing imperatives ØLimitations in the physics of materials ØSpecial considerations ØChanges in manufacturing technologies ØConditions for quality-testing the product Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 10

Strategic Quality Planning Quality and Innovation in Product and Process Design The Design Process ØStep 4 Technology development for process selection ØStep 5 Final product definition ØStep 6 Product marketing and distribution perpetration ØStep 7 Product design and evaluation ØStep 8 Manufacturing system design ØStep 9 Product manufacture, delivery and use Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 11

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) The House of Quality A method for translating customer requirements into functional design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 12

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 1. Develop a list of customer requirements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 13

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 2. Develop a listing of technical design elements along the roof of the house Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 14

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 3. Demonstrate the relationships between the customer requirements and technical design elements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 15

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 4. Identify the correlations between design elements in the roof of the house Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 16

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 5. Perform a competitive assessment of the customer requirements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 17

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 6. Prioritize customer requirements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 18

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 7. Prioritize technical requirements Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 19

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) QFD Step by Step: 8. Final evaluation Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 20

Strategic Quality Planning Quality and Innovation in Product and Process Design Quality Function Deployment (QFD) The Houses of Quality Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 21

Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Designers tools: A square A pencil A drafting Table Replaced by ----- Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 22

Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Computer Aided Design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 23

Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Computer Aided Design And Multi-user CAD Systems Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 24

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 Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 25

Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD Geometric Modeling Engineering analysis Interface checking Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 26

Strategic Quality Planning Quality and Innovation in Product and Process Design Technology in Design CAD/CAM Computer-aided Inspection Computer-aided Testing Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 27

Strategic Quality Planning Quality and Innovation in Product and Process Design Other Design Methodologies Ø Ø Organizing the Design Team The Product Life Cycle Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 28

Strategic Quality Planning Quality and Innovation in Product and Process Design Other Design Methodologies Ø Ø Ø Product families and the Product Life Cycle Complementary products Designing products that work Design for the manufacture method Design for maintainability Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 29

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø Failure Modes and Effects Analysis (FMEA) 1. 2. 3. 4. 5. Improvement of safety, quality and reliability Improvement of a company’s image Increased user satisfaction Reduction in product development cost Record of actions taken Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 30

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø Where FMEA can be applied 1. 2. 3. 4. 5. Concept Process Design Service Equipment Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 31

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø How FMEA works 1. 2. 3. Give each component in the system a unique qualifier List all functions each part of the system performs List the one or two failure modes for each function Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 32

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø How FMEA works 4. 5. 6. Describe the effect of each failure mode of the component. Determine whether the failure will result in a hazard. Estimate the relative likelihood of occurrence for each failure on a 10 point scale. Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 33

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø How FMEA works 7. 8. 9. Estimate the ease with which the failure may be detected Use the estimates from steps 5, 6 and 7 to identify the highest risks Decide what action will be taken to eliminate or reduce the likelihood… Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 34

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø Fault Tree Analysis An analytic tool which graphically renders the combination of faults that lead to the failure of a system Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 35

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø 1. 2. 3. 4. Failure Modes, Effects and Criticality Analysis (FMECA) A description of the products functions Listings of the potential failure modes Potential effects each failure mode could have Potential causes of each failure mode Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 36

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø Failure Modes and Effect Analysis (FMEA) Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 37

Strategic Quality Planning Quality and Innovation in Product and Process Designing for Reliability Analysis Tools Ø Ø Fault Tree Analysis (FTA) Failure Modes, Effects, and Criticality Analysis (FMECA) Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 38

Strategic Quality Planning Quality and Innovation in Product and Process Design Product Traceability and recall Procedures Product Traceability and Recall Procedures Ø Ø Ø Product traceability Recall procedures Consumer Product Safety Commission (CPSC) Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 39

Strategic Quality Planning Quality and Innovation in Product and Process Design Environmental Considerations in Design Green Manufacturing Ø Ø Ø Design for reuse Design for disassembly Design for remanufacture Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 40

Strategic Quality Planning Quality and Innovation in Product and Process Design Summary ØDesigning products for quality ØThe Design Process ØQuality function deployment (QFD) ØTechnology in design ØOther Design Methodologies ØDesigning for reliability ØProduct traceability and recall procedures ØEnvironmental considerations in design Copyright © 2013 Pearson Education, Inc. Publishing as Prentice Hall. 7 - 41

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