quality in product and process design pertemuan 13-14 matakuliah: perancangan manajemen mutu tahun:...
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Quality in Product and Process Design Pertemuan 13-14
Matakuliah : Perancangan Manajemen MutuTahun : 2009
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Chapter 7:Quality in Product and Process Design
Reference:S. Thomas Foster, “Managing Quality: An Integrative
Approach”, Second Edition, Pearson Prentice Hall, New Jersey, 2003
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Quality in Product and Process Design
• Designing Product for Quality • Quality Fuction Deployment (QFM) • Technology in Design • Prototyping Methodologies • Design for Reliability • Environmental Consideration in Design• Discussion and Questions
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Designing Product for Quality
• In design product we must first many Questions• What does it mean to design products for Quality
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Project Development Process
• Product idea generation• Customer future needs projection• Technology selection for product• Technology development for process selection• Final product definition• Product market and distributioaration• Product design and evaluation• Manufacturing system design• Product manufacture, delivery and use(See Figure 7-1, Project Development Process)
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Quality Fuction Deployment (QFM)
• See Figure 7-2, QFD Layout: The House of Quality:– Technical Requirements– Customer Requirements– Competitive Assigment
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The Steps in Performing a QFD
• Develop a list customer requirement• Develop a list of technical design elements along the roof of
the house• Demonstrate the relationships between the customer
requirements and technical design elements.• Perform a competitive assessment of the customer
requirements• Prioritize customer requirements• Prioritize technical requirements• Final evaluation
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Technology in Design
• Computer Aided Design (CAD) system– Multiuser CAD Systems– Geometric Modeling– Engineering Analysis– Design Review– Interface Checking– Group Technology
• Computer Aided Inspection (CAI)• Computer Aided Testing (CAT)
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Prototyping Methodologies
• Organizing the Design Team• The Product Life Cycle• Product Families and the Product Life Cycle (See
Figure 7-13, Cumulatives Product Family Life Cycle)
• Complementary Products• Design for Manufacture (DFM)• Design for Maintenability
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Design for Reliability
• Failure Modes and Effects Analysis (FMEA)– Improvement of the safety, quality, and the realibility of
product– Improvement of a company’s image and its competitiveness– Increased satisfaction from user standpoint– Reduction in product development cost– Record of actions taken to reduce a product risk
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FMEA Steps
• Assign each component an identifier• List functions for each part• List one or two failure modes for each fuction• Describe effects of each failure mode• Determine hazards likelihood and catagorieze• Estimate likelihood of failure• Estimate failure detection• Identify hightest risk• Elimanate or reduce highest risk
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Design for Reliability
• Reliability Analysis Tools– Failure Modes and Effects Analysis (FMEA)– Fault Tree Analysis – Failure Modes, Effects, and Criticality Analysis (FMECA)
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Design for Reliability
• Failure Modes and Effects Analysis (FMEA)– Method for systematically considering each component of a
system, identifying, analyzing, and documenting the possible failure modes within a system and the effect of each failure on the system.
• Benefits of FMEA– Improvement of product safety, quality, and reliability.– Improvement of a company’s image and competitiveness.– Increased satisfaction from a user standpoint.– Reduction in product development cost.– Record of action taken to reduce a product risk.
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Design for Reliability
• Basic areas where FMEA can be applied– Concept: FMEA is used to analyze a system or its subsystems in
the conception of the design.– Process: FMEA is applied to analyze the assembly and
manufacturing processes.– Design: FMEA is used for analysis of products before mass
production of the product begins.– Service: FMEA is used to test industry processes for failure prior
to their release to customers.– Equipment: FMEA can be used to analyze equipment before the
final purchase.
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Design for Reliability
FMEA Steps Figure 7.18
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Design for Reliability
• Fault Tree Analysis– An analytical tool that graphically renders the combinations of
faults that lead to the failure of the system. – This technique is useful for describing and assessing the events
within a system.
• Primary Symbols of Fault Tree Analysis– Events– Gates
• Gates– Link the faults to the undesired events within the diagram.
Gates show how faults are related.
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Design for Reliability
• Types of Events (in Fault Tree Analysis)– Basic events are initiating faults that do not require events below
them to show how they occurred. The symbol used for a basic event is a circle.
– An intermediate event is the result of a combination of faults, some of which may be primary events.
– This intermediate event is located in the middle of a fault tree. These events are described by rectangles.
– An expanded event requires a separate fault tree because of its complexity. For this new fault tree, the expanded event is the undesired event and would be located at the top of the fault tree.
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Design for Reliability
Fault Tree Diagram
Figure 7.20
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Design for Reliability
• Steps in Fault Tree Analysis– Become familiar with the system.– Define the undesired events of the system with the related
contributing and initiating events.– Develop fault trees for the undesired events.– Obtain probabilities for the events on the fault trees.– Evaluate fault trees.– Analyze the results and proposals for system improvement.– Change the fault trees to reflect proposed improvements
and renewed fault tree evaluation.– Perform a worst case analysis.
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Design for Reliability
• Failure Mode, Effect, and Criticality Analysis (FMECA)– An extensive, but simple method for identifying ways in which
an engineered system could fail.
• Criticality– In FMECA is important because it prioritizes how the design
team should be spending its resources.– In general, criticality refers to how often a failure will occur,
how easy it is to diagnose, and whether it can be fixed.– Critically assessment is somewhat subjective because it
depends on the viewpoint of a service or field analysis.
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Design for Reliability
• Product Traceability– The ability to trace a component part of a product back to its
original manufacturer.
• Consumer Product Safety Commission (CPSC)– An independent federal regulatory agency that helps keep
American families safe by reducing the risk of injury or death from consumer products.
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Environmental Conditions in Design
• Importance– Currently, society demands much more from product designers
than just high-quality products. Many manufacturers have turned to a more environmental form of manufacturing that offers positive returns on investment.
• Green Manufacturing– Movement that began in Germany with requirements for
importers to remove packaging materials.
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Environmental Conditions in Design
• Design for Reuse– Designing products so they can be used in later generations of
products.• Design for Disassembly
– A method for developing products so that they can easily be taken apart.
• Design for Remanufacture– A method for developing products so that they parts can be used
in other products. Associated with green manufacturing.
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Discussion and Questions
• Case 7-1:– Designing the Ford Taurus: Why Quality Had to be Job 1
• Case 7-2:– Nucor Corporation: Producing Quality Steel by Stressing
Sound Management Practices