Modeling and Simulation Workshop 2007 Modeling Simulation and

Modeling and Simulation Workshop 2007 Modeling & Simulation and the Way We Work Yesterday, Today, and Tomorrow Mark Enzien with help from Jan Enderle and Debbie Gualtieri October 3, 2007

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow WHY Modeling & Simulation? Q C D • Achieve higher levels of Quality • Match Customer needs more directly Modeling and Simulation Workshop 2007 • Fewer Hardware Iterations • Less Hardware • Easier to Optimize Cost & Performance Mark Enzien October 3, 2007 • Less Time to Optimize • Faster to Iterate • Less Rework Page 2

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow o o o Modeling & Simulation and the Way We Work What did, does and will it look like? Yesterday • Subject Mater Experts with pockets of Expertise • Lots of tools distributed and used in isolation • Critical Parameter / Manufacturing Tolerance focused Today • Functional, Wide Spread Expertise • Uniform training and rollout of common tools • Support and Recognition at all levels of Management • Optimization of hardware modules • Plenty of early Results and Success Tomorrow • System Excellence • Bred into our early procedures --Tied to our results • Customer & System Test simulations • Fewer hardware builds and iterations Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 3

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow YESTERDAY Our troubles seemed so far away Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 4

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow o o Lots of engineers created models and simulations to do their work • Paper Path Timing • Image to Paper Registration • Image on Image Registration • Power Consumption • Frame Rigidity and Deflection • TIPP Timing and Productivity Techniques and Approaches shared in a Community of Practice More powerful CAD systems enabled interactive design, latitude work, and tolerance analysis Design concepts and “simulations” were routinely analyzed on the tube Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 5

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow o o o Critical Parameter Management championed by Maurice Holmes 20 years ago FITS installed by John Elter 25 years ago TC/Tribo has been a guiding Xerographic model (since I joined the company) Electronics design (PWBA’s, Gate Arrays) have benefited from real time simulations for decades – very few errors prior to fabrication Software test cases became common place in the real time community Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 6

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow But it was not “The Way We Worked” Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 7

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow TODAY Everyone is doing it Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 8

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Df. LSS Tools / Best Practices o o o o o Quality Function Deployment (QFD) Measurement System Analysis (MSA) Concept Generation & Selection Design of Experiments (DOE) Robust / Parameter Design Expected Value Analysis (EVA) Statistical Process Control (SPC) Descriptive Sampling All Pairs / High Throughput Testing Modeling & Simulation Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 9

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 10

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Complex Person-by-Person Deployment Planning PDU Sr. Team and Program Managers Df. LSS SW Deployment in FFPS Marking and Imaging Competency Center Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 11

w/Significant Payback Sustaining w/Payback Adoption • Part of Org DNA Prod. Families/ Value Chain • Cross org teams • MBB/BB Leadership development • Cross discipline teams • Integrate Df. LSS with Products Product Delivery • Reward and Recognition Process • Management GBs and BBs • Critical mass Subsystems • Leadership selection model • Certification part of career path for BBs and MBBs • Customize: Make it yours • Full-time MBBs • Identify & train early Adopters Buy-in I mple me nta tion M a turity / C o m p l e x i t y Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow • Effective training/coaching/application • Deployment and functional mgrs full partnership • Create early wins Individual Projec • Modify if you don’t get a strong “pull” • Set expectations: Plan for “bumps in the road” • Leaders with vision/patience Individual Studie • Make it safe to share/ learn from success • Principle-based strategy and failures, celebration T i m e Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 12

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Project Nuvera EA Toner Integration with SCMB Developer Housing and Nuvera Xerographics Team (Leader) From PDU: Mary Schlitzer / Jason Pino / Matt Fabrizio / Jyothsna Ram / Jen Rea / Coretta Akinnawo / Adelina Bravo-Medina / Pat Medina / Dave Lomenzo / Mike Soures / Bob Pozniakas / John Buzzelli / Jerry Lioy / Jeff Drawe / Dave Ahl / Dave Kamprath / Erwin Ruiz From PSDU: Ajay Kumar / Hiro Oba In concert with SDU Accomplishments o Transfer functions developed for key toner / sub-system interfaces o Optimization achieved in record time o Product achieved step function in reliability Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 13

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Project Sorrento Custom Color Dry Blending (Firenze) Team (Leader) From PDU: Jim Winters / Dave Stookey / Kip Jugle / Erin George / Kristin La. Due / Dan Bishop / Carmen Sofia From SDU: John Ianni / Julia Kohlmeier / Jeanne Smith / Don Hilliard / Bill Hollenbaugh Accomplishments o Reduced 167 critical parameters and 55 output characteristics to 8 design rules through transfer function development o New color development in days vs. months o Over 70 colors in sales catalog (MAPS) to date Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 14

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Project Delphinus XIAO 2 Team (Leader) From PDU: Brian Conrow / Jim Calamita / Bob Herloski / Paul Hosier / Stu Schweid / Doug Taylor / Shawn Updegraff From XIG: Claude Fillion / Howard Mizes / Ken Ossman / Peter Paul / Enrique Viturro / Stan Wallace Accomplishments o Predicted performance characteristics before seen experimentally (e. g. dithering at low area coverage and TRC linearity as a source of incomplete correction) o Provided means to better understand experimental performance in presence of noisy system (e. g. system correction limits and sensor mounting tolerance sensitivity) o Saved >$800 K retooling costs for image module by demonstrating upgrades were not required to correct sensor chip mounting errors o Analytical DOE helped identify critical imaging module parameters Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 15

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Project Cayman Gloss Design Selection Team (Leader) Beatriz Custode / Joe Hancock / Brendan Williamson / Yelena Shapiro / Mike Martin / Maria Barden / Mary Schlitzer / William Hollenbaugh / Doug Kreckel / Christine Keenan / Gina Lo. Verde / Debbie Gualtieri / Norm Robinson / Susan Ashley / David Van. Bortel / Eddy Dalal / Matt Tanaka / Brian Mc. Namee / Mark Smith Accomplishments o Demonstrated current gloss performance using Design of Experiments and Expected Value Analysis o Completed benchmarking and visual assessments to understand customer needs / gloss acceptability o Explored design options for lowering gloss level o Applied Combinex decision process and tool to select best design option to meet customer and business needs Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 16

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Project FFPS (Docu. SP) Build Frequency Improvement Team (Leader) FFPS Engineering Focus Team Accomplishment o Increased frequency of successful system builds from roughly once a week to an average of ten times a week while reducing build time from a minimum of four hours to a minimum of 2 minutes. Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 17

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Everyone / Anyone can Do IT PTol & PTot should be less than 0. 1 Resolution should be greater than 5 Conclusion: Measurement technique is not adequate Too much error due to reproducibility and repeatability Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 18

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow N~ (1, (0. 0000001)2) Paper Quadrant (same, different) Paper Condition (Fan fold, Pieces) U~ (-1, +1) Noise Factor Oil on Document Sample Preparation / Extraction Process M. E. Kerosene (15 ml, 25 ml) N~ (20, (0. 025)2) N~ (-1, (0. 0000001)2) Even Extraction Time (16 hr, 48 hr) N~ (16, (0. 0555)2) Note: Actual oil levels are greater than the high level achieved in the DOE. Need to explore if recommendation holds for higher oil levels. Range (mg) USL = 0. 006 mg Optimum Settings: Extraction Time = 48 hr Kerosene = 15 m. L Paper Quadrant = different Paper Condition = Fan fold Oil level (0. 01, 0. 02) Optimized EVA Baseline EVA Mean = 0. 0018 Stdev = 0. 0008 Cpk = 1. 701 Mean = 0. 0044 Stdev = 0. 0008 Cpk = 0. 651 Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 19

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow TOMORROW The Way Work gets Done Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 20

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow FIT Leaders CTC’s / CTX’s derived from VOC / VOX SE / CPM V-Model CTC’s / CTX’s Solution Owners Concept Generation & Selection Solutions Req. Flow-down, System Optimization & Capability Roll-up Position Papers, Solution Design & Optimization FIT / CTC Reviews & Tollgates (Performance Outlook) Solution Reviews & Tollgates (Delivery Outlook) CTC / Solution Matrix becomes Program Guide of WHATs to HOWs Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 21

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Critical Parameter Management V-Model LSL Predict & Validate DCO System Performance Predicted, Optimized, Validated! ty U p System Partitioning # of proof cycles Color stability Ro Predict & Validate % match to proof ll C apa bili Predict & Validate Subsystem Interfaces & (Inputs/Outputs) USL Cascade to Contours § § § Accuracy Calibration Solution owners predict and validate solutions FIT Leader optimizes system performance Customers find prints pleasing! Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 22

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow Enterprise-wide deployment R&D Engineeri ng Faciliti es Human Resources Sales and Marketing Xerox Administrati on Customer Communicati ons Informatio n Technologi es Operation s Finance Manufacturi ng Our view: Not just a tool for operational efficiency, but an enterprise-wide business strategy for creating real value Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 23

Modeling & Simulation and the Way We Work: Yesterday, Today, and Tomorrow We Can Get it Done Modeling and Simulation Workshop 2007 Mark Enzien October 3, 2007 Page 24