Chapter 13

Quality by

Design

Quality by Design

Definition Benefits Teams Communication Models Tools Misconceptions and Pitfalls Exemplary Organizations

Definition

...practice of using a multidisciplinary team to

conduct conceptual thinking, product design, and product

planning all at one time.pg. 349

RUBE GOLDBERG

Benefits

Faster product development Better quality Less work in progress Fewer engineering change orders Increased productivity Decreased time to market pg. 353

Teams

Take advantage of existing experience Emphasize early high-quality decisions Support customer requirements Feedback constraints Efficient management of risk and change as

product moves from design to sales. pg. 353

Communications Models

Organizational StructureWho talks to whoStraight line hierarchy (traditional)Cross-talk hierarchy (TQM structure/Information paths)pg. 356

Straight Line Hierarchy

Figure 13-3, pg. 356

Cross-talk Hierarchy

Figure 13-4, pg. 357

Tools

TQM philosophiesComputer networksISO standards (9000 and 14000)

Total Productive Maintenance

Quality function deployment

Information Technologies (IT)

Electronic meeting software

Enterprise resource planning software

pg. 359

Production Tools

Robotics CAD/CAM/CMC Just-in-time production Virtual planning and manufacturing software Lean Manufacturing Advanced measurement and verification

pg. 356

Misconceptions and Pitfalls

Not simultaneous design and production Not a “quick fix” or “magic formula” for success Does not require multiple tests of product until

optimum design achieved. Not to replace or be confused with inspection

protocols and programs

pg. 371

Misconceptions and Pitfalls

Avoid using team members improperly Avoid promises to meet unobtainable goals or

schedules Avoid tight tolerances or stringent requirements

for one-pass design Avoid changes in product during design phase Avoid business as usual with “low-bid” vendors Avoid automation before simplification

Exemplary Organization

TRIDENT CORP

Trident Corp

Founded in 1979. Manufactures precision sheet metal components, electromechanical

assemblies, and custom products in medical, office-equipment, computer, and defense

industries.

pg. 372

Trident “Quality”

“quality as a basic business plan” for both short and long term goals.

Quality, cost, delivery, and service.

Trident Strategies

Design qualityTeam efforts with partners and suppliersRegular contact with suppliers and customersEmployee ownership of projectsCross-functional teams / Job diversificationAcknowledgment and RewardGuarantees of Product Performance

pg.373