OMIS 430 Exam 2

Necessity & importance of Product Design

Product must be designed for "Manufacturability"
KISS= Keep it Simple and Safe.
1. Affects Quality.
2. Affects Costs.
3. Affects Customer satisfaction.
4. Affects functionality of product.
5. Affects reliability of product.

Reasons for Product Design

1. To increase business
2. To be competitive
3. Availability of new technology, materials, etc.

Reasons for Product Redesign

1. Customer complaints/dissatifaction
2. Excessive accidents/injuries.
3. Low demand
4. Availability of new raw materials or tech.
5. To comply with new gov't regulations or safety
6. To improve quality
7. Recent trends

Design Objectives

1. Achieve customer satisfaction
2. Design for manufacturability
3. Design for operations
4. Redesign to reduce costs, recycle, increase value, remanufacture.

Design Process

1. Begin with an idea
2. Product specifications
3. Prototype development and market test
4. Product introduction and follow-up

Where can an Idea for design come from?

- customers
- suppliers
- competition

Two types of Research

1. Basic
- advancing the knowledge
2. Applied
- some goal of commercial application in mind.

Product Life Cycle

1. Introduction
2. Growth
3. Maturity
4. Saturation
5. Decline
most critical design features must be perfected in the early part of the life cycle.

Degree of Standardization

0%= High Variety (high cost)
100%= Low Variety (low cost)

Standardization

helps make a design simpler and cheaper but can make it be less appealing to the customers b/c of reduced variety.

Approaches to design

1. Design for manufacturability
2. Design for assembly
3. Design for recycling
4. Design for remanufacturing
5. Robust design (most important today)

Robust Design

Design that results in a products/services that can function over a broad range of conditions regardless of who uses them.

Taguchi;s approach to design

often easier to design a product that in insensitive to environmental factors, either in manu or in use than to control these enviro. or user-related factors.

Central features of Taguchi's Approach

is "Parameter Design". Involves determining the specification settings for both the product an the process that will result in robust design.

Product Reliability

Is defined as the ability of the product or system to perform its intended function under a prescribed set of conditions. Thus, it is
a.) Ability of the product to perform its intended function
b.) Important aspect of product design
c.) Important aspect of competitiveness.

Ways to improve Reliability

1. Better component design
2. Better production/assembly techniques
3. Better testing of products or services
4. Using back-ups
5. Better user education
6. Better system design

Improving the Design Process

1. Concurrent engineering: bringing together design, marketing, manu and testing people- allowing all to work closely together thru design phase.

2. Computer Aided Design (CAD): creating products using computer graphics.

Modular Design

-Products are put together as modules. Modules consist of several components.
-Form of standardization.
-Offer easier diagnosis, repair, replacement.
- Can be costly

Customer Focus and Design

-Products and services must be designed to satisfy the customers by giving them what they want.
-Usually vague in telling us what they really wants.
-Sometimes they dont know, and we can use QFD

Quality Function Deployment (QFD)

1. Integrates voices of customers in design process
2. Relates customer requirements to their corresponding tech features or requirements.
3> Is in the form of a matrix (also called house of quality)

Service Design

1. Most services involve interaction with customer. this makes service design delicate and difficult.
2 Minimize customer contact
3. Service requirements vary from customer to customer.
4. Many services are difficult to describe.
5. thus, many service must be highly customized.
6. Services cannot be inventoried
7. Response time very critical.

Reliability

Is the probability that a component or product or a system will function.
-Is an important focus in product design.

Two ways of computing reliability

1. function when activated.
2. function for a given length of time.

Way 1 of computing reliability

probability that a product will function in one single trial.
Three types of Arrangement

1. Series: all components must function for product or system to work

2. Parallel: all components do not have to function simultaneously, bc system uses back-ups or redundancy.

3. Hybrid: combination of series and parallel.

Way 2 of computing reliability

probability that the product will function for a given length of time.

-No failure before T =

-Failure before T =

Failure Rate Profile

Shows variation in failure rates with time. Failure rate is high earlier b/c the defective products fail right away
- CURVE KNOW AS "BATH TUB" CURVE.

Quality

Ability of a product or service to consistently meet or exceed implicit and explicit customer expectations.

Modern Quality Management

places emphasis on preventing mistakes rather than on finding them and correcting them.
-responsibility of everyone in the organization

Dimensions of Quality

-Quality does not pertain to a single aspect of a product; different aspects may be important to different people
-performance
-special features
-durability
-etc...

Determinate of Quality

a)The design
--inclusions or exclusions of certain features
b) Conformance to design
--well designed, but is it well made?
c) Ease of use
--instructions of use, pictures?
d) Service after delivery
--product may not perform as intended.

Consequences of Poor Quality

a) Loss of business
b) Liability
c) Loss of productivity
d) Other consequence

Quality Gurus

1. W. Shewhart- father of statistical quality control. Control charts
2. W.E. Deming-
-14 point program
-special causes of variation
-common causes
-reduce variation to improve quality
3. J.M Juran
-defined quality as fitness for use.
-quality trilogy
4. Phil Crosby
-goal to be zero defects
-do right the first time
5. K. Ishikawa
-cause and effect diagram
-quality circles
6. G. Tanguchi
-robust design
-quality loss function

Deming's 14 Points

-Create constancy of purpose for improving products and services.
-Adopt the new philosophy.
-Cease dependence on inspection to achieve quality.
-End the practice of awarding business on price alone; instead, minimize total cost by working with a single supplier.
-Improve constantly and forever every process for planning, production and service.
-Institute training on the job.
-Adopt and institute leadership.
-Drive out fear.
-Break down barriers between staff areas.
-Eliminate slogans, exhortations and targets for the workforce.
-Eliminate numerical quotas for the workforce and numerical goals for management.
-Remove barriers that rob people of pride of workmanship, and eliminate the annual rating or merit system.
-Institute a vigorous program of education and self-improvement for everyone.
-Put everybody in the company to work accomplishing the transformation

Major Quality Awards

-Baldridge Award: given by US gov't to U.S businesses.
-European Quality Award: organizational excellence.
-Deming Prize: given by Japanese gov't, anyone in the world can get it.

Quality Standards

ISO-9000: European Standards
- series of international standards
- Document everything they do towards quality.
- critical to international business.

ISO-14000: Environmental Performance
- international standards for assessing compants enviro performance.

MIL-SPEC: Militart Specifications
- very first quality standards developed

What is TQM

is an organization wide effort to achieve quality

three basic fundamentals of TQM

1. customer focus
2. Process Improvement
3. Total involvement

Other important elements of TQM include

1. Continuous improvement
2. Employee Empowerment
3. competitive benchmarking
4. Supplier quality
5. knowledge of quality tools
5. Quality at source

Six Sigma

is a business process for improving quality, reducing costs and increasing customer satisfaction. Program designed to reduce occurrence of defects in design, production, service, and delivery, to lower cost, save time, and improve customer satisfaction.

8 Tools of TQM

1. check sheets
- for recording/organizing data to id problems.
2. flowcharts
-visual representation of the steps.
3. scatter diagrams
- a graph that shows the degree & direction of relationship between two variables.
4. Histograms
- a chart of empirical frequency distribution
5. Pareto analysis
-classifying problems by degree of importance.
6. Control charts
-monitor if process is in control
7. Cause and effect
-used to search for cause of problem.
8. run charts
- tracking results over a period of time.

quality tools for generating ideas

1. Brainstorming
2. Quality circles
3. interviewing
4. Benchmarking
5. 5W2H Questioning approach

3 Approaches to Quality Assurance

1. Inspection before and after production
2. Inspection during production for corrective action
3. Building quality into the process.

Role of Inspection

-helps detect bad products
-does not correct the defects.
-basically undesirable
-does not add value
-must be minimized

Inspection basic questions and issues

How much?
-little as possible
When?
-benefits exceed the cost
Where?
-raw materials (before)
-finished gods (after)

Source Inspection

Where employees self-check their own work.

Statistical Process control (SPC)

Statistical evaluation of process output during production
-involves periodically taking small size samples from the process and comparing sample results with a predetermined standard. -if sample result are not acceptable, the process is stopped and corrective action is taken.
-Every process exhibits variability.

Common/random/chance

-causes normal variation

Special/assignable/correctable

cause abnormal (special) variations

Normal/natural variation

inherent variations, due to chance or is minor error.
-said to be "in control"

Abnormal/special variation

cause can be identified, such as tool wear, operator fatigue, lack of training.
-said to be "out of control"

Control Charts

are time ordered plot of sample statistics used to distinguish between normal and abnormal variability.

Control Charts for Variables Data

1. Mean chart: is for motoring mean of the process output.
2. Range chart: monitors range (variability ) of process output.

-these charts should be used together to check and keep process in control.