a powerful problem or opportunity analysis technique · 2008-11-02 · 1.) project scope is a lead...
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© G. A. Motter, 2006 & 2008
Function Definition
A Powerful Problem or OpportunityAnalysis Technique
© G. A. Motter, 2006 & 2008
© G. A. Motter, 2006 & 2008
Test & ValidateAssess Performance, Reliability, Mfg, ...
OK
Capture & Analyze Voice of the CustomerIdentify Critical Customer Requirements (CCRs)&
Establish System Level Engineering Specifications
Design for ManufacturabilityMinimize Sensitivity to Mfg Variations
Design for Robust PerformanceMinimize Sensitivity to Design & Operating Variations
Predict QualityPredict Iterate to Meet Quality Target
Identify System Design ConceptDetermine System Functionality
Flow Down of CCRs to Sub-Assemblies and parts
Develop Detailed DesignRelate CCRs (Ys) to Design Parameters (x’s)
OK
Deliver to Customer
Optimizefor 6
Validate
Design
IdentifyCCRs
Define
Define the ProjectBusiness Case, Opportunity Statement, Goal,
Scope and Boundaries
Typical
DFSS
Process
Source: Design for Six Sigma, K. Yang
© G. A. Motter, 2006 & 2008
Objectives
• Learn “Best Practices” to Define Functions
• Identify Basic and Secondary Functions
• Develop a FAST Diagram
• Intro. to Value Engineering
• Assign Homework
FAST: Function Analysis System Technique
© G. A. Motter, 2006 & 2008
Function Definition
• A description of a product expressed as an ActiveVerb and a Measurable Noun
• Provides a complete understanding of the basicreason(s) something exist
• Explore new ways to deliver Customer Satisfaction– Improved performance
– Lower cost
© G. A. Motter, 2006 & 2008
Steps to Function Definition
1. Define Project Scope
2. Define the Functions
3. Construct the FAST diagram
4. Perform FAST diagram logic checks
Source: Value Management, J. Kaufman
FAST = Function Analysis System technique
© G. A. Motter, 2006 & 2008
1.) Project Scope is a Lead Pencil
LEAD
PAINT
BODY
BAND
ERASER
PENCIL
COMPONENTS
This product couldThis product couldbe anything:be anything:•• Power SupplyPower Supply
•• Circuit BreakerCircuit Breaker•• Data BaseData Base•• SoftwareSoftware•• Radar SetRadar Set•• etc.etc.
Source: Value Management, J. Kaufman
© G. A. Motter, 2006 & 2008
2.) Define the Functions for your Project
Functions are defined in two word phrases
• Active Verb:
– Describes the specific action we plan to carry out to achieve our intendedpurpose
• Measurable Noun
– Defines the object on which the action operates
• Any Verb may be combined with any Noun to describe adesired Function
Acid Test – “Does it describe what somethingactually does in the system under study?”
© G. A. Motter, 2006 & 2008
Verbose Descriptions Indicate Lack ofDesign Understanding
Reduce Size
Educate Students
Create Image
Control Deflection
Collect Dirt
Collect Data
Attract Attention
Remove CD
Stop Automobile
Steer Automobile
Start Engine
Suppress Noise
Cut Grass
Transmit Information
Save Time
Reward Achievement
Tighten Bolt
Protect Children
Prevent Contamination
Maintain Clearance
Increase Incentive
Establish Budget
© G. A. Motter, 2006 & 2008
Verbs to Avoid
Passive and Indirect Verbs
Goal-Like Verbs
AttendReview
PrepareFurnishSupply
IsGiveProvide
Economize
MinimizePresent
PrioritizeMaximizeLeast
Optimize“ize” wordsImprove
© G. A. Motter, 2006 & 2008
Tips for Active Expressions
• Important to use active Verbs rather than passive Verbs
• To change passive description to active, try using the nounas the verb and select another noun
Resolve ProblemDetermine Resolution
Budget ExpensesSubmit Budget
Exhibit ProductsDevelop Exhibits
Approve ProceduresSeek Approval
Support WeightProvide Support
ActivePassive
Functions are intended to be taken literally as we attempt to bringclarity in describing WHAT a system actually does
Exam
ple
s
Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping
© G. A. Motter, 2006 & 2008
Function Description Of A Lead Pencil
PencilComponents
Description
ERASER Remove Marks
BAND Secure EraserImprove Appearance
BODY Support LeadTransmit Force
Accommodate Grip
PAINT Protect WoodImprove Appearance
Display Information
Deliver Message
LEAD Make Marks
Source: Value Management, J. Kaufman
© G. A. Motter, 2006 & 2008
3.) Every Design has Basic andSecondary Functions
Basic Function:• Principal reason for the product’s existence
• Has value to the Customer
• Loss of Basic Function results in total loss of market value forthe design
• May be Performance or Esteem based
Secondary Function:• Assist in, or necessary for, the realization of a Basic Function
• Targets for modification and/or elimination to:
– Reduce cost
– Reduce design complexity
– Achieve Breakthrough in design
Source: Value Management, J. Kaufman
© G. A. Motter, 2006 & 2008
Basic and Secondary Functions Of A Pencil
PencilComponents
Description Functions
(Basic or Secondary)
ERASER Remove Marks Secondary
BAND Secure Eraser SecondaryImprove Appearance Secondary
BODY Support Lead SecondaryTransmit Force Secondary
Accommodate Grip Secondary
PAINT Protect Wood SecondaryImprove Appearance Secondary
Display Information Secondary
Deliver Message Secondary
LEAD Make Marks Basic
Source: Value Management, J. Kaufman
Why someonebuys a pencil
© G. A. Motter, 2006 & 2008
3) Construct the FAST Diagram
Why do a FAST Diagram?
– Help understand whichFunctions provide the bestopportunities to beeliminated, or improved, todeliver the BasicFunction(s)
FAST Diagram
– Visual layout (Tree Diagram) of theproduct’s Functions
– Starts with the Basic Function, and buildsto the right with supporting or SecondaryFunctions
© G. A. Motter, 2006 & 2008
Construct FAST Diagram Left to Right,and Check it Right to Left
1. Identify what you feel is the Basic Function.2. Place Secondary Functions to the right of the Basic Function. Ask the
question: “How is this Function actually accomplished?”3. Check the FAST diagram by starting at the right and working left. Ask the
question: “Why must this Function be performed?”
Basic Function
Secondary Function
Secondary Function
Secondary Function
Secondary Function
Secondary Function
Source: Value Management, J. Kaufman
AND logic
OR logic
Ask How ?
Ask Why ?
© G. A. Motter, 2006 & 2008
Example: Lead Pencil FAST Diagram
KeepRecords
MaintainInformation
RecordInformation
MakeMarks
DepositMedium
ApplyPressure
SupportLead
ProtectWood
SecureEraser
TransmitForce
Accommodate
Grip
CorrectInformation
RemoveMarks
AbsorbMedium
ApplyPressure
RubEraser
ImproveAppearance
DisplayInformation
Ask How ?
Ask Why ?
© G. A. Motter, 2006 & 2008
Example Mouse Trap
Objective: Eliminate Mice
KillMouse
StrikeMouse
ReleaseStriker
TripTrigger
ArmTrap
PositionStriker
SetTrigger
BaitTrap
AttractMouse
ReleaseEnergy
StoreEnergy
CompressSpring
Ask Why ?
Ask How ?
© G. A. Motter, 2006 & 2008
ProduceSlicedHam
EnsureFlavor
EnhanceAppearance
FabricateSlices
Space Meat Length
Determine MeatWeight
Remove Fat
Remove Casing
Form Meat
Remove Air Bubbles
Adjust Meat Color
Spread Flavoring
Sliced Ham Process
Source: Function Analysis, K. Akiyama, pg 207
Example: Inject Brine
Retain Brine
AddColoring(to Meat)
TenderizeMeat
Lower MeatTemp
Fix MeatThickness
Add Flavoring
© G. A. Motter, 2006 & 2008
Four Rules of FunctionDefinition
1. Once defined, the Basic Function cannot change; itbecomes the principle work the system does.Example: A flashlight is expected to emit light
2. The cost contribution of a Basic Function is usuallyminimal percentage of total cost
3. Can not sell supporting Secondary Functions withoutperforming the Basic Function satisfactorily
4. Loss of Basic Function(s) causes loss of marketvalue. Example a Rolex watch that does not displaycorrect time
© G. A. Motter, 2006 & 2008
4.) FAST Diagram LogicChecks
Double check tree diagram “How?” and “Why?” logic.
Identify possible Secondary Functions for elimination?
Test by removing Secondary Function, and ask the“How ?” and “Why ?” logic questions.
Check “AND” logic and “OR” logic diagramming.
Ensure project Scope lines are clearly drawn.
© G. A. Motter, 2006 & 2008
Cost Function Matrix is Workhorse ofValue Engineering
Functions come fromdetailed level of FASTDiagram
Total
%
Operations, Parts,
Assembly
Total
Cost
Functions (V-N)
Operations, Parts, andassemblies come from:
- Block diagram- Process Map- Logic Diagram- Value chain
© G. A. Motter, 2006 & 2008
Cost – Function Matrix IdentifiesAreas of Opportunity
Steps to Create Matrix:
1.) List major operations, parts, or assemblies in lefthand column
2.) List total cost for each group in adjacent column3.) Place Functions across top from FAST Diagram4.) Identify Functions contributing to each line of cost
(indicate with dot in cell)5.) Determine portion of cost associated with each
function6.) Sum Functional cost7.) Calculate Function %8.) Show Function % on FAST diagram
© G. A. Motter, 2006 & 2008
Example: International North Atlantic Ice Patrol
• Formed in 1913• Result of Titanic sinkingApril 14, 1912
• Iceberg condition data collected by• Fixed wing aircraft• Buoys
• Report warnings at 9 pmeach day in “plain, conciseEnglish” during ice seasonfrom February thru July.
© G. A. Motter, 2006 & 2008
Example:International Ice
Patrol
Source: Value - Its Measurement, Design, and Management by M.L. Shillito Fig 7.7
Send IcebergWarnings
TransmitRadio
Messages
CompileMessages
LocateIcebergs
PredictIcebergPosition
PurchaseSensors
HireOperators
MoveOperators
MoveSensors
Receive ShipData
Collect Data
Predict IceDrift
OperateRadio
EstablishStation
Ask How ?
Ask Why ?
© G. A. Motter, 2006 & 2008
Example: International Ice PatrolCost-Function Matrix
Note: Cost in 1983 dollarsSource: Value – Its Measurement, Design, and Management by M.L. Shillito, Fig 7.8
Total
Cost $M Pu
rch
ase
Sen
so
rs
Hir
eO
pera
tors
Mo
ve
Op
era
tors
Mo
ve
Sen
so
rs
Receiv
eS
hip
Data
Co
llect
Data
Pre
dic
tD
rift
Esta
bli
sh
Sta
tio
ns
Op
era
te
Tra
nsm
itte
r
Aircraft Personel 705 235 235 235
Fuel 494 247 247
Aircraft Maintenance 490 245 245
Aircraft Op. Support 152 76 76
Office Staff 224 56 56 56 56
Travel/Lodging 50
Leasing 5 1 4
Bouys 63 63
Radar Film 13 13
Misc. 5 5
Admin. 480 120 120 120 120
Total $2,681 77 235 853 803 176 176 176 9 176
% 100 2.9 8.8 32 30 6.5 6.5 6.5 0.3 6.5
© G. A. Motter, 2006 & 2008
Example: International Ice Patrol
Source: Value - Its Measurement, Design, and Management by M.L. Shillito Fig 7.7
Send IcebergWarnings
TransmitRadio
Messages
CompileMessages
LocateIcebergs
PredictIcebergPosition
PurchaseSensors
HireOperators
MoveOperators
MoveSensors
Receive ShipData
Collect Data
Predict IceDrift
OperateRadio
EstablishStation
$2,496,000
$185,000
$2,056,000
$440,000
$2,681,000(1983)
2.9%
8.8%
32%
30.0%
6.5%
6.5%
6.5%
6.5%
0.3%
Ask How ?
Ask Why ?
Target for costreduction
© G. A. Motter, 2006 & 2008
Homework Assignment
Objective
• Develop a FAST Diagram for your ECE 480 Senior Design Project
Instructions
• Provide a few sentences describing your Senior Design Projectdesign objectives to orient me in grading this homework assignment
• Follow Step-By-Step process in slides
• Refer to examples in Slides and Appendix
• Refer to Appendix for list of useful Verbs and Nouns
• Only diagram a maximum of 3 levels of Secondary Functions beyondBasic Function
Deliverables
• Typed FAST Diagram in Microsoft Word, Excel, or PowerPoint foreach Team
• E-Mail Diagram to G. Motter at [email protected] and to Dr.Goodman
Due Date
• October 6, 2008
© G. A. Motter, 2006 & 2008
© G. A. Motter, 2006 & 2008
Questions?
© G. A. Motter, 2006 & 2008
Appendix
Classical Text Book Examples
© G. A. Motter, 2006 & 2008
Useful Verbs in Describing Functions
SelectLocateDevelop
RotateIsolateDestroy
ReverseInvertCool
RetainInsulateConvert
ResistIncreaseControl
VerifyRemoveImplementConduct
UseReduceHeatContain
TransportRecordHardenConfirm
TransmitRecommendFreezeCombine
TestProtectExtendCollect
SupportPreventExpandCreate
StorePositionEvaluateAttach
StartObtainEliminateArrange
SeparateMeasureDistributeAnalyze
SenseMaintainDisplayAdd
© G. A. Motter, 2006 & 2008 Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping
© G. A. Motter, 2006 & 2008
Useful Nouns in Describing Functions
TextureMotionExpansion
TemperatureMoistureEnvironment
StressMobilityEnergy
SpaceMixtureEnclosure
SoundMaterialDistance
WeightSolidLengthCurrent
WearSizeInformationComponent
WaterShapeIndicationCommunication
WasteRotationHumidityComfort
VoltageResistanceHeatColor
VolumeResistanceGasCold
VibrationProtectionFrictionAtmosphere
VehiclePressureFrequencyAssembly
TorqueOpeningForceArea
TimeNoiseFluidAir
© G. A. Motter, 2006 & 2008 Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping
© G. A. Motter, 2006 & 2008
Ask Why ?LocateSheet
Pierce Sheet
AdjustHoles
Collect Waste
Attract UserProhibit Rust
Protect Work Surface
Drop Holes
Collect Holes
Locate Punch Assembly
Retract Punch
Guide Punch
Drive Punch
Support SheetPaper Punch
Source: Acquiring, Processing, and Deploying the Voice of the Customer, M. Shillito, pg 74
Example:
ProduceHoles
BasicFunction
Ask How ?
Scope
OrganizePaper
Task
Decorate Surface
© G. A. Motter, 2006 & 2008
FAST Model is complete when Customer Needs can beMapped to Secondary Functions
SecondaryFunction
1. Need2. Need
SecondaryFunction
1. Need2. Need3. Need
SecondaryFunction
1. Need2. Need
CustomerTask
BasicFunction
SF
SF
1. Need
SF
SF
SF
SF
1. Need
Ask How ?
Ask Why ?
© G. A. Motter, 2006 & 2008
Mapping of Voice Of Customer to FunctionsExample: Paper Punch
Locate Sheet• Easy to insert• Stays in place
Pierce Sheet• Easy to press• Won’t hurt hand• Pierce multiple sheets• Non-jamming
Adjust Hole (location)• Easy access to assembly• Easy to position• Finger tight• Stays in place
Collect Waste• Holds large quantity of holes• Holes won’t fall out• Easy to clean
ProduceHoles
© G. A. Motter, 2006 & 2008 Source: Function Analysis, K. Akiyama, pg 55
Function Tree - Flashlight
Ask How ?
Ask Why ?Example:
Convert Electricityto Light
Open/closecircuit
Form Circuit
Store ElectricalEnergy
Reflect Light
Adsorb Force
Fit Grip
Collect Light
Hold Bulb
Protect Bulb
Send Current
Generate Light
House Parts
IlluminateSurroundings
Hold Body
RetainAppearance
BasicBasicFunctionFunction
© G. A. Motter, 2006 & 2008
Verbose Descriptions Indicate Lack ofDesign Understanding
Organize DataSpreadsheet
Convert CurrentRectifier
Store InformationFlash Memory
Limit CurrentFuse
Illuminate SurroundingsLED Array
Verb Noun
Function DefinitionObject
© G. A. Motter, 2006 & 2008
Appendix
Past ECE 480 Project Examples
© G. A. Motter, 2006 & 2008
Detect IceLevel
OutputHeight
TaskBasic
Function
DisplayLED
DecodeImage
SenseEnvironment
HaveInformation
Have PowerSource
DecodeInformation
TransferImage
HaveAlgorithm
CapturePicture
Emit Light
Have PowerSource
Time ImageCapture
Have IceBin
PrepareCamera
Havealgorithm
CloseFreezer Door
Stop IceMaker
Refrigerator IceLevel Detection
© G. A. Motter, 2006 & 2008
MeasureHeight
Locate BrimOf Object
DetermineDistance
ActivateSensingSystem
DetectObject
Collect Data
UseAlgorithm
Send Signal
CalculateVoltageChange
DisplayObjectHeight
(inches)
Convert AnalogSignal to Digital
Signal
Implementand Run
Code
© G. A. Motter, 2006 & 2008
Team 13 Digital Answering MachineFAST Diagram
Detect Rings Connect Line
Answer Phone Detect Dial-tone Disconnect Line
Receive Messages Store Messages Record Audio Digitize Signal
Basic Function Secondary FunctionsStore Date/time
Volume Control Amplify Audio
Playback Messages Convert Message Retrieve Message
Display Date/time Retrieve Date/time
© G. A. Motter, 2006 & 2008
ECE480Active EMI Filter
ReduceConducted
Noise
ReduceLow Frequency
Noise
ReduceHigh Frequency
Noise
SenseNoise
AmplifyNoise
Correct For NoiseError
Combine withExisting Noise
Increase SeriesImpedance at High
Frequencies
Short HighFrequency Noise
To Ground
Couple to FilterInput
MeasureSystem Error
CompensateAmplifierFor Error
UseInductors
UseCapacitors
Cancel Currents
Cancel Voltages
Design EMI Filter forAutomotiveApplication
Pass DC throughFilter
© G. A. Motter, 2006 & 2008