1 this week lab form design teams and decide what you’ll design this week homework qfd; design...
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THIS WEEK LAB
Form design teams and decide what you’ll
design
THIS WEEK HOMEWORK
QFD; Design Specifications
Read:
PDS and QFD
PDS and QFD ES1050 lecture
CDEN2006
Install SolidWorks2011
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1. Specification Development / Planning PhaseDetermine need, customer and engineering requirementsDevelop a project plan
2. Conceptual Design PhaseGenerate and evaluate conceptsSelect best solution
3. Detail Design PhaseCAD modelsEngineering drawingsDesign documentationPart specification
Prototype and testing
4. Production PhaseComponent manufacture and assemblyPlant facilities / capabilities
5. Service PhaseInstallation, use , maintenance and safety
6. Product Retirement PhaseLength of use, disposal, and recycle
This is the extend of MME2259a design project
Production, service and retirement phases consideration will have an impact on the MME2259a design project, especially in the detailed design phase.
ENGINEERING DESIGN PROCESS
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DESIGN INFLUENCES THE FOLLOWING:
Product Quality
Product Manufacturing Cost
Product Cost
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DESIGN INFLUENCE ON PRODUCT QUALITY
Quality is a composite of factors that are responsibility of the design engineer.
Decisions made during the design process determine the product’s quality as perceived by the customers.
Quality cannot be built into a product unless it is designed into it
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DESIGN INFLUENCE ON MANUFACTURING AND PRODUCT COST
Specification
Development
Conceptual
DesignDetailed Design
Time
100
60
0
20
40
80
Note that ¾ of the product cost associated with design is committed by the end of the
conceptual design phase
Early design decisions have the greatest effect on the final product cost.
% of product manufacturing cost
committed
% of product cost committed
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DESIGN PROCESS PARADOX
Time into Design Process
Freedom
Knowledge of Design
Design Freedom
100%
0%
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SEQUENTIAL VS. CONCURRENT PRODUCT DEVELOPMENT
Sequential Product Development should be avoided
Marketing Research and Development
Engineering Manufacturing
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SEQUENTIAL VS. CONCURRENT PRODUCT DEVELOPMENT
Concurrent Product Development is preferred
Marketing
Research and Development Engineering
ManufacturingService
Voice of customer
Satisfaction of customer needs
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WE ARE NOW READY TO DESIGN A PRODUCT
BUT HOW DO WE KNOW THAT CUSTOMERS WILL BUY IT?
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Time was when a man could order a pair of shoes directly from the cobbler. By
measuring the foot himself and personally handling all aspects of manufacturing,
the cobbler could assure the customer would be satisfied
http://www.qfdi.org
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As marketing requested it
As sales ordered it As engineering designed it
As production manufactured it
As plant installed it What the customer really wanted !!
TODAY MANUFACTURING HAPPENS VERY FAR FROM CUSTOMERS,
IT’S EASY TO LOST TOUCH ...
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IMPORTANCE OF CUSTOMER RESEARCH
Customer research is essential to developing any new
product or service. Without a complete understanding of
your customers’ wants and needs, you may be developing a
product that is out-of-sync with your market and ultimately
doomed to failure.
http://www.ams-inc.com/
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DIFFERENT WAYS TO FIND WHAT CUSTOMERS NEED AND WANT
Use existing feedback
Surveys
Customer interviews
Competitive analysis
Just ask them
• Actual ways companies use to find customers’
needs and wants are tightly guarded trade secrets!
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• Must be discriminatory• Must be measurable• Must be orthogonal: no overlapping of requirements,
each requirement should identify a unique feature• Must be universal: applicable to all alternatives under
consideration• Must be external to problem: must not impose design
choices
CUSTOMER REQUIREMENTS
WHAT?
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Must be discriminatory
CUSTOMER REQUIREMENTS
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Must be measurable
CUSTOMER REQUIREMENTS
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CUSTOMER REQUIREMENTS
Must be orthogonal: no overlapping of requirements, each requirement should identify a unique feature
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CUSTOMER REQUIREMENTS
Must be universal: applicable to all alternatives under consideration
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CUSTOMER REQUIREMENTS
Must be external to problem;must not impose design choices
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WE SATISFY CUSTOMER REQUIREMENTS BY DESIGNING
A PRODUCT THAT IS CHARACTERIZED BY CERTAIN
SPECIFICATIONS
PRODUCT
DESIGN SPECIFICATION
HOW?
CUSTOMER
REQUIREMENTS
WHAT?
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PRODUCT DESIGN SPECIFICATIONS
HOW
Other names for engineering design specifications include:• Engineering design specifications• Engineering requirements• Design requirements• Functional requirements• Objectives and constraints• Technical requirements• Technical specifications
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PRODUCT DESIGN SPECIFICATION (PDS) LIST
Is a detailed summary of the design requirements to be met in order to produce a successful product or process.
BASIC APPROACH TO CREATE PDS
Write a separate specification for each element of the PDS list.
If possible, the specification should be expressed in quantitative terms, and when appropriate it should give limits within which acceptable performance lies.
Performance attributes may be divided into:
(i) attributes that must be satisfied(ii) attributes that you want to satisfy
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PRODUCT DESIGN SPECIFICATIONS (PDS) LIST
1. Performance - List the functions to be performed by the product, and the desired level of performance (eg. engineering requirements, targets, specifications).
2. Operating Environment - Specify the operating environment for the product (eg. range of temperature, pressure range, abuse by operator, etc).
3. Standards - List relevant standards that must be adhered to (eg. ANSI, ASTM, CSA, ISO)
4. Materials - Poorly chosen materials can lead to product failure or unnecessary costs (eg. material performance characteristics, key material properties)
5. Customer - List any information on customer likes, dislikes, preferences, and prejudices (customer driven design)
6. Ergonomics - Identify any man-machine interfaces (eg. need for handles, buttons, displays…).
7. Aesthetics, Appearance and Finish - Consider color, shape, texture, and form at the onset of the design (this is what the customer sees first).
8. Competition Benchmarking - Perform a thorough analysis of existing and future competitors (determine how the customer perceives the competition’s ability to meet each design requirement).
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9. Quality and Reliability - High risk areas of the product should be identified, and the risks minimized using formal trade-off techniques in the design process (product must meet or exceed customer’s expectations).
10. Testing and Inspection - Specify the tests required to demonstrate that the product meets the desired specifications, and any quality requirements.
11. Maintenance and Logistics - Specify ease of access to the components likely to require maintenance (speed and ease of repair can influence customer’s acceptance of the product).
12. Service Life - Establish the expected service life and operation duty cycle for the product (How long is it expected to last while in operation).
13. Market Constraints - List any feedback from the marketplace.
14. Target Product Cost - Establish selling cost at the onset of the design process (Retail price is often 3X manufacturing cost for mass produced items).
15. Quantity - Estimate the number of products to be produced (cost/unit to fabricate is influenced by production method).
16. Product Life Span - Predict how long the product is to remain on the market (influences investment decisions, potential sales).
PRODUCT DESIGN SPECIFICATIONS (PDS) LIST
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17. Shelf Life in Storage - Consideration must be made for protecting parts from the natural elements while not in use (some products must be stored on hazardous sites for prolonged periods of time).
18. Size - This is an important constraint for shipping, storage and marketing.
19. Weight - An important factor in handling a product on the manufacturing floor, transportation and installation (weight is related to size and cost).
20. Shipping - Determine how the product will be delivered to the customer (size of box cars, weight on transport trucks).
21. Packaging - Specify the type of packaging required for shipping and storage (protection during transportation, display).
22. In-House Processes - Identify any specified treatment of parts (eg. heat treatment, water resistant coating).
23. Manufacturing Facilities - Determine whether the product is to be produced in an existing facility or a new plant must be built (effects design choices such as materials and shape, directly effects cost).
24. Patents - Consult all areas of useful information prior to launching the design (prevent costly lawsuits).
PRODUCT DESIGN SPECIFICATIONS (PDS) LIST
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25. Design Schedule - List definite milestones that the design team is required to meet (schedule adequate time to due design activity, testing).
26. Company Constraints - Any constraints imposed by company must be spelled out (limits on new plant investments, preferred vendors/suppliers).
27. Social and Political Factors - List any constraints arising from government regulation (eg. pollution laws, seatbelt legislation, …).
28. Safety - Critical parts whose failure will cause injury must be identified and documented (Warning labels should be devised and operating manuals should clearly spell out what is abusive use of the product).
[Ullman 1992]
PRODUCT DESIGN SPECIFICATIONS (PDS) LIST
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YOU WILL HAVE TO DEVELOP DESIGN SPECIFICATIONS
CONSIDERING THESE 28 FACTORS
1. Performance
2. Operating Environment
3. Standards
4. Materials
5. Customer
6. Ergonomics
7. Aesthetics, Appearance and Finish
8. Competition Benchmarking
9. Quality and Reliability
10. Testing and Inspection
11. Maintenance and Logistics
12. Service Life
13. Market Constraints
14. Target Product Cost
15. Quantity
16. Product Life Span
17. Shelf Life in Storage
18. Size
19. Weight
20. Shipping
21. Packaging
22. In-House Processes
23. Manufacturing Facilities
24. Patents
25. Design Schedule
26. Company Constraints
27. Social and Political Factors
28. Safety
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PRODUCT DESIGN SPECIFICATION: A WATER MIXER TAP
Selected specifications:
Maximum pressure 15 bar
Maximum temperature 60OC (standard) 100OC (short time)
Flow 20L/min
Service life 8 years
These specifications are input for a designer’s analysis of the required functionality and constraints.
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Functions: Meter
Stop
Adjust
Mix
Inputs: Pressure
Flow rate
Temperature of hot and cold water
Outputs: Pressure
Flow rate
Temperature of mixed water
The specification is an input for a designer’s analysis of the required functionality and constraints.
For example:
The flow of water is either stopped or metered such that the mixed temperature can be adjusted to any desired value regardless of the water flow rate. Furthermore, the water flow rate must remain unchanged as temperature changes.
PRODUCT DESIGN SPECIFICATION: A WATER MIXER TAP
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PRODUCT DESIGN SPECIFICATION: AN ELECTRIC TOOTHBRUSH
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PRODUCT DESIGN SPECIFICATION: A SEAT SUSPENSION
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WE NOW KNOW WHAT ARE CUSTOMERS NEEDS AND WE KNOW
HOW TO DEVELOP PRODUCT SPECIFICATIONS TO MEET THOSE
NEEDS.
HOWEVER, DESIGN PROCESS IS FULL OF TRADE-OFFS AND NOT
ALL SPECIFICATIONS CAN BE FULLY SATISFIED. WE NEED A WAY
TO PRIORITIZE THOSE SPECIFICATIONS.
WE ALSO NEED A QUANTITATIVE WAY TO COMPARE OUR (YET
TO BE DESIGNED) PRODUCT TO EXISTING COMPETITIVE
PRODUCTS.
HOW DO WE CONNECT CUSTOMERS’ NEEDS TO PRIORITIZED
DESIGN SPECIFICATIONS?
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WE SATISFY CUSTOMER REQUIREMENTS BY DESIGNING
A PRODUCT IS CHARACTERIZED BY CERTAIN SPECIFICATIONS
PRODUCT
DESIGN SPECIFICATION
HOW?
CUSTOMER
REQUIREMENTS
WHAT?
QFD LINKS CUSTOMER REQUIREMENTS WITH
PRODUCT DESIGN SPECIFICATIONS
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Deployment:
The distribution of forces in preparation for battle or work
QUALITY FUNCTION DEPLOYMENT (QFD)
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QFD was developed to bring this personal interface to modern manufacturing
and business. In today's industrial society, where the growing distance between
producers and users is a concern, QFD links the needs of the customer (end
user) with design, development, engineering, manufacturing, and service
functions.
Quality Function Deployment is a technique developed in Japan during the mid-
1970's for better understanding the design problem, in particular of customer
needs and to relate them to product design specifications.
QUALITY FUNCTION DEPLOYMENT (QFD)
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AN INFLATABLE KAYAK
In class exercise
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STEPS IN QFD EXERCISE
1. Identify the customers
2. Determine the customers' requirements: What do the customers want?
3. Determine relative importance of the requirements
4. Generate engineering specifications: How will the customers' requirements be met?
5. Relate customers requirements to engineering specifications
6. Identify relationships between engineering requirements
7. Identify and evaluate the competition: How satisfied is the customer now?
8. Set engineering targets: How much is good enough?
AN INFLATABLE KAYAK
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ENGINEERING
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CORRELATION
MATRIX
WHO?
1. Identify customers:
Who are they?
QFD Chart also called HOUSE OF QUALITY
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2. Determine customers’ requirements:
What do customers need and want?
ENGINEERING
REQUIREMENTS
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CORRELATION
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3. Determine the relative importance of
customers’ requirements.
ENGINEERING
REQUIREMENTS
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CORRELATION
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WHO?
4. Generate engineering requirements (PDS):
How will the customers’ requirements be met?
ENGINEERING
REQUIREMENTS
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CORRELATION
MATRIX
WHO?
5. Relate customers’ requirements to
engineering requirements
ENGINEERING
REQUIREMENTS
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WHO?
6. Identify relationships between
engineering requirements
ENGINEERING
REQUIREMENTS
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7. Identify and evaluate competition.
How satisfied is the customer now?
ENGINEERING
REQUIREMENTS
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8. Set engineering targets
How much is good enough?
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HAVE WE MET OUR TARGETS AT THE
END OF THE DESIGN PROCESS?
Beginning of design
process: PDS
End of design
Process: Prototype
?
We’ll do this at the end of the design project
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Competitor A Competitor B
AN INFLATABLE KAYAK
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AN INFLATABLE KAYAK
76 73
Mass
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DESIGN INFLUENCE ON PRODUCT COST
Specification Development
% of product cost committed
Conceptual Design
Detailed Product Design
Time
100
60
0
20
40
80
Having completed the design specification phase we
have already committed 40% of product cost!
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1. Product Planning- Translating what the customer wants (in their language, e.g., portable, convenient phone service) into a list of prioritized product/service design requirements (in your language, e.g., cell phones) that describes how the product works. It also compares your performance with your competition's, and sets targets for improvement to differentiate your product/service from your competitor's.
2. Part Planning - Translating product specifications (design criteria from step 1) into part characteristics (e.g., light weight, belt-clip, battery-driven, not-hardwired but radio-frequency based).
3. Process Planning - Translating part characteristics (from step 2) into optimal process characteristics that maximize your ability to deliver Six Sigma quality
4. Production Planning - Translating process characteristics (from step 3) into manufacturing or service delivery methods that will optimize your ability to deliver Six Sigma quality in the most efficient manner (e.g., cellular antennas installed with overlapping coverage to eliminate dropped calls).
FOUR PHASE QFD APPROACH
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Product Planning
Component Design
Process Planning
Production Planning
FOUR PHASE QFD APPROACH
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TWO PHASE QFD APPROACH
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LOG SPLITTER
Partial PDS
Size of log
Width
Diameter
Time to split
Type of wood (pine, oak, …)
Weight
Portability
Terrain?
Max towing speed?
…
Customer requirements
Any log size
Works fast
Tow-able
Lightweight
Inexpensive
Last forever
…
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