Design For Quality - Achieving 0 PPM With SigmundWorks From EGS India

Design for Quality: Achieving 0 Rejection A Reality
Natarajan R
Director
EGS India
Agenda
Introduction to Design For Quality DFQ Checklist for DFQ Dimensional Management Techniques Predicting Assembly Build Automating Inspection Process Summary
www.egs.co.in www.egsindia.com
Introduction to DFQ What Tolerance to allocate? How will the tolerances affect function? Will there be any assembly issues? What will be the PPM estimates? Is it really necessary to tighten tolerances? Have I chosen the right tolerance? Am I responsible for increasing the product Cost?
Did You Know? Only about 60% of new products launched are actually a success and that for every seven new product ideas, only four make it to development and then only one succeeds.
Source: Winning at New Products: Accelerating the Process from Idea to Launch - Robert G. Cooper
DFQ: Definition of Paradigm Superior Functionality Best Fit Least Rejections Highest Customer Satisfaction Consistent Performance
Quality Issues Parts not aligning well for a perfect Fit Vibration & Noise due to moving parts Inconsistent Life & Performance under Controlled Testing Unpredictable Field Failures
Improper Fit
Vibration - Effects
Vibration & Noise
Field Failures
Six Sigma Approach
Design for Six Sigma (DFSS) Objective is to Understand the Root Cause and Eliminate Defects Maximize Return on Investment Incorporate Processes for Continuous Improvement Enables Gap Analysis of entire Product Development System Addresses Voice of Customer (VOC)
5 Steps in DFSS
Planenable the team to succeed with the project by mapping all vital steps Identifyhear the voice of the customer to select the best product concept Designbuild a thorough knowledge base about the product and its processes Optimizeachieve a balance of quality, cost, and time to market Validatedemonstrate with data that the voice of the customer has been heard and that customer expectations have been satisfied
DFSS Another Perspective

Definedetermine the project goals and the requirements of customers (external and internal) Measureassess customer needs and specifications Analyzeexamine process options to meet customer requirements Designdevelop the process to meet the customer requirements Verifycheck the design to ensure that its meeting customer requirements
SS Vs DFSS
DMAIC is more focused on reacting, on detecting and resolving problems, while DFSS tends to be more proactive, a means of preventing problems. DMAIC is for products or services that the organization offers currently; DFSS is for the design of new products or services and processes. DMAIC is based on manufacturing or transactional processes and DFSS is focused on marketing, R&D, and design.
Checklist for DFQ

Is the Drawing Correct? Is the Drawing Complete with Respect to Functional Tolerancing? Has Process Capability been incorporated while selecting Tolerances? Has Assembly Build Criteria been defined? Has Interference Analysis been performed? Have Critical Dimensions for Assembly Build been identified? Have tolerances been maximized for required Assembly Build? Have Tolerances been optimized for least cost? Is the PPM Estimate meeting our Business Profitability Objective? Is there a Dimensional Verification Plan?
Dimensional Management Techniques Develop G D & T / Plus-Minus Tolerancing Schematic using DimXpert inside SolidWorks Perform Assembly Build Analysis using SigmundWorks inside SolidWorks Update SolidWorks Drawing with Optimized Tolerances Establish CMM Inspection Program automatically from SolidWorks Drawing using PAS-CMM for SolidWorks
GD&T
Vs Plus/Minus Tolerancing
Geometric Tolerancing
Plus/Minus Tolerancing
GD&T Drawings using DimXpert
Answers to Quality Challenges

CAD Part Geometry Product Specification
Tooling Geometry
Process Capability
Assembly Sequence & Index Plan
Measurement Plan
Dataset Tolerances, Datum and GD & T
Cost Optimized Tolerance Cost Drivers Tolerances
PPM Estimation
Key Characteristics
Inspection Dimensions
Performance www.egs.co.in www.egsindia.com
Dimensional Management Plan Assured Quality on adherence to DM Plan Eliminates Cost due to Poor Quality Ensures Quality in First Prototype !
Tolerance Analysis Vs Tolerance Synthesis
Setting Build Objectives
Setting Build Objectives
Defining Node Tree of Dimensions & Tolerances
PPM Estimates
Identifying Contributors
Incorporating Process Capability
Updating SolidWorks Drawings
Establishing Dimensional Inspection Process with PAS-CMM
Automated CMM Programming from 3D CAD Designs Reduces CMM Programming time by 90% Eliminates ambiguity in drawing interpretation
Summary of Benefits
Correctness & Completeness of Drawings assured Assembly Issues are eliminated Maximized Tolerancing for Least Cost Identification of Critical Dimensions affecting Assembly Build & Performance Estimate Rejections a priori Establish Dimensional Inspection FREE OF ERRORS Eliminates customer rejection of parts/ assemblies Ensures Consistent Quality Reduces/ Eliminates Human errors in subjective interpretation of drawings that result in re-work, time delays and escalates product cost
Thank You
Interested in Design for Quality? Contact: info@egs.co.in Web: www.egsindia.com www.egs.co.in


Design For Quality - Achieving 0 PPM With SigmundWorks From EGS India

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Design For Quality - Achieving 0 PPM With SigmundWorks From EGS India

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Design for Quality: Achieving 0 Rejection A Reality

Vibration & Noise

Six Sigma Approach

DFSS Another Perspective

Checklist for DFQ

GD&T Drawings using DimXpert

Answers to Quality Challenges

Assembly Sequence & Index Plan

Dataset Tolerances, Datum and GD & T

Cost Optimized Tolerance Cost Drivers Tolerances

Performance www.egs.co.in www.egsindia.com

Tolerance Analysis Vs Tolerance Synthesis

Setting Build Objectives

Setting Build Objectives

Defining Node Tree of Dimensions & Tolerances

Incorporating Process Capability

Updating SolidWorks Drawings

Establishing Dimensional Inspection Process with PAS-CMM

Interested in Design for Quality? Contact: info@egs.co.in Web: www.egsindia.com www.egs.co.in

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