Training Presentation on Design Training Presentation on Design ControlControl

Ryan McLaughlinRyan McLaughlin

OISM 470WOISM 470W

Design ControlDesign ControlWhat Will Be CoveredWhat Will Be Covered

• Definition of Design ControlDefinition of Design Control• Technology In DesignTechnology In Design• Taguchi MethodTaguchi Method• BenchmarkingBenchmarking• QS 9000QS 9000• SummarySummary

Definition of Design ControlDefinition of Design Control

Design Control – “A set of steps Design Control – “A set of steps focused on managing the design of focused on managing the design of a product.”a product.”

Brainstorming ExerciseBrainstorming Exercise

Think of how much money your Think of how much money your organization spends on error organization spends on error correction each year.correction each year.

Implementing a Design Control Implementing a Design Control system can cut long term costs as system can cut long term costs as well as improve quality and well as improve quality and eliminate waste.eliminate waste.

Technology In DesignTechnology In Design

In today’s changing world, In today’s changing world, technologies like Computer Aided technologies like Computer Aided Design (CAD) have emerged as the Design (CAD) have emerged as the standard tool in designing new standard tool in designing new products.products.

Brief Overview of CADBrief Overview of CAD

• Can be used to simulate real-world Can be used to simulate real-world situations.situations.

• Multi-User CAD systemsMulti-User CAD systems• Design ReviewDesign Review• Computer Aided Inspection (CAI)Computer Aided Inspection (CAI)• Computer Aided Testing (CAT)Computer Aided Testing (CAT)

Why Implement a CAD System?Why Implement a CAD System?

• Reduce costsReduce costs• Improve Accuracy of DesignImprove Accuracy of Design• Improve Accuracy of TestingImprove Accuracy of Testing• Overall Improvement in QualityOverall Improvement in Quality

The Taguchi MethodThe Taguchi Method

The Taguchi Method for quality The Taguchi Method for quality improvement is named after Dr. improvement is named after Dr. Genichi Taguchi who first Genichi Taguchi who first introduced the method at AT&T introduced the method at AT&T Bell Laboratories in 1980.Bell Laboratories in 1980.

The Taguchi MethodThe Taguchi Method

The Taguchi Definition of QualityThe Taguchi Definition of Quality• differs from traditional definitions of differs from traditional definitions of

qualityquality• Taguchi said Taguchi said Ideal QualityIdeal Quality is delivered is delivered

when “a product or service performs its when “a product or service performs its intended function throughout its intended function throughout its projected life under reasonable projected life under reasonable operating conditions without harmful operating conditions without harmful side effects.”side effects.”

The Taguchi MethodThe Taguchi Method

• Robust DesignRobust Design

products should be designed products should be designed so that they are free of all defects so that they are free of all defects and are of the highest quality.and are of the highest quality.

Robust DesignRobust Design(The Taguchi Method)(The Taguchi Method)

Three Step Method for Creating Three Step Method for Creating Robust DesignsRobust Designs

• Concept DesignConcept Design• Parameter DesignParameter Design• Tolerance DesignTolerance Design

Concept DesignConcept Design

• Deals with the design of the Deals with the design of the process. process.

• Properly selecting process Properly selecting process components and methods can components and methods can reduce costs and increase the reduce costs and increase the quality of the finished product.quality of the finished product.

Parameter DesignParameter Design

• Deals with finding the optimal levels of Deals with finding the optimal levels of variables that management can control variables that management can control in a process.in a process.

• Parameter design does not usually affect Parameter design does not usually affect production costs, but rather attempts to production costs, but rather attempts to find the best level of performance for find the best level of performance for the system.the system.

Tolerance DesignTolerance Design

• Refers to finding the acceptable Refers to finding the acceptable variation limits after the parameter variation limits after the parameter design has been established.design has been established.

• Usually results in an increase in Usually results in an increase in production costs, but also an production costs, but also an increase in production quality.increase in production quality.

Robust Design StepsRobust Design Steps

In order to create a robust design, In order to create a robust design, the following steps are used to the following steps are used to incorporate the three perspectives incorporate the three perspectives Taguchi states.Taguchi states.

Steps for Creating a Steps for Creating a Robust DesignRobust Design

1. Identify the 1. Identify the main Functionmain Function

2. Identify the 2. Identify the noise factors noise factors and testing and testing conditionsconditions

3. Identify the 3. Identify the quality quality characteristics characteristics to be observed to be observed and the and the objective objective function to be function to be optimizedoptimized

4. Identify the 4. Identify the control control factors and factors and their their alternative alternative levelslevels

5. Design the 5. Design the matrix matrix experiment and experiment and define the data define the data analysis analysis procedureprocedure

6. Conduct the 6. Conduct the matrix matrix experimentexperiment

7. Analyze the 7. Analyze the data and data and determine near determine near optimum levels optimum levels for the control for the control factorsfactors

8. Predict the 8. Predict the performance performance at these at these levelslevels

BenchmarkingBenchmarking

Another method that can be helpful Another method that can be helpful in creating high quality designs is in creating high quality designs is benchmarking. benchmarking.

A benchmark is a company which is A benchmark is a company which is recognized for being the best in a recognized for being the best in a certain field.certain field.

BenchmarkingBenchmarking

• Companies model themselves after the Companies model themselves after the benchmark corporations in their specific benchmark corporations in their specific field.field.

• The initiator firm might contact the The initiator firm might contact the target firm for information and statistics target firm for information and statistics to be used for improvement of both to be used for improvement of both corporations.corporations.

BenchmarkingBenchmarking

There are six types of benchmarking.There are six types of benchmarking.• Process BenchmarkingProcess Benchmarking• Financial BenchmarkingFinancial Benchmarking• Performance BenchmarkingPerformance Benchmarking• Product BenchmarkingProduct Benchmarking• Strategic BenchmarkingStrategic Benchmarking• Functional BenchmarkingFunctional Benchmarking

QS 9000QS 9000

• QS9000 is a supplier development QS9000 is a supplier development programprogram

• Provides a supplier standard for auto Provides a supplier standard for auto companiescompanies

• QS9000 has a requirement dealing with QS9000 has a requirement dealing with design controldesign control

QS 9000QS 9000

The Design Control Requirement of The Design Control Requirement of QS9000.QS9000.

• Suppliers must be qualified in value Suppliers must be qualified in value engineering, geometric tolerance engineering, geometric tolerance and dimensioning, and the Taguchi and dimensioning, and the Taguchi Method.Method.

QS9000 – A Real World ExampleQS9000 – A Real World Example

• A team of representatives from GM, A team of representatives from GM, Ford and Chrysler developed the Ford and Chrysler developed the QS9000 standard, including the QS9000 standard, including the standard for design control. standard for design control.

• Suppliers to these auto Suppliers to these auto manufactures need to be QS9000 manufactures need to be QS9000 certified. certified.

Exercise Exercise

• Write down the approximate annual cost of Write down the approximate annual cost of error correction and losses due to poor quality error correction and losses due to poor quality in your organization.in your organization.

• Now calculate approximately how much a Now calculate approximately how much a design control system such as CAD would cost design control system such as CAD would cost to implement.to implement. A QMS/ISO9000 Design control A QMS/ISO9000 Design control system can cost between $10,000 and system can cost between $10,000 and $500,000, depending on the size of the $500,000, depending on the size of the corporation.corporation.

• Consider that it could be free to employ the Consider that it could be free to employ the Taguchi Method and also improve quality and Taguchi Method and also improve quality and cut costs.cut costs.

SummarySummary

• Design Controls can help improve Design Controls can help improve quality and cut costs.quality and cut costs.

• Free ideas like the Taguchi Method are Free ideas like the Taguchi Method are harder to implement but can pay off in harder to implement but can pay off in the end.the end.

• Technology like CAD systems can also Technology like CAD systems can also aid in design qualityaid in design quality

BibliographyBibliography

• http://mijuno.larc.nasa.gov/pap/robdes/robdes.htmlhttp://mijuno.larc.nasa.gov/pap/robdes/robdes.html “ “DESIGN DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN APPROACHAPPROACH.” By Resit Unal and Edwin B. Dean.” By Resit Unal and Edwin B. Dean

• ““Managing Quality, An Integrative Approach” By S. Thomas Managing Quality, An Integrative Approach” By S. Thomas FosterFoster

• ““Plant and Service Tours in Operations Management” by Roger Plant and Service Tours in Operations Management” by Roger W. Schmenner W. Schmenner

• http://manufacturing.software-directory.com/software-2.cdprodhttp://manufacturing.software-directory.com/software-2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Control.ISO.9000.41/014/863.QMS.Programs..ISO.9000.Design.Control.ISO.9000.44.shtml4.shtml QMS PROGRAMS /ISO 9000 DESIGN CONTROL (ISO 9000/4.4) QMS PROGRAMS /ISO 9000 DESIGN CONTROL (ISO 9000/4.4)