Session 14

Recap of Lecture 13

Begin Module 1

Summary

Module 6

Quality Function Deployment

Module 5

Implementation
Tools

Quality by Design

Module 4

Teams
Communication

Quality by Design

Module 3

Sequential vs. Concurrent Design

Module 2

Recap of Lecture 13

Module 1

Agenda

Rajiv Gupta
BITS Pilani
Lecture 14

MMVA ZG 522 Total Quality

Management

End of Module 1

Lecture 14

Deming felt that most design of experiment texts ignored

the difference between analytical and enumerative
studies
Only stable processes have predictable outcomes. Any
attempt to make future predictions based on a current
sample is statistically incorrect.
The experimental design approach we have followed
takes a PDSA perspective where at each successive
iteration our degree of belief in the effect of a change is
further increased, or not
Lecture 13 dealt with multi-factor design of experiments

Recap of Lecture 13

Lecture 13 was the second lecture on the design of

experiments
In design of experiments, we proactively test the effect of
changes to the system
The approach to the design of experiments covered in
lectures 12 and 13 did not follow the method in the text
book. However, it is based on the teachings of Deming
It is based on a book by Ronald Moen, who was asked to
write the book by Deming.

Recap of Lecture 13

From: Kolarik

Classic Sequential Product

Development Process

Traditionally, the design and development process in

organizations has followed a sequential approach.
Each functional department completes its task, almost in
isolation, and tosses its solution to the subsequent
department.
If a problem is found at a subsequent stage, it is tossed back
to the earlier department to make corrections and the
process is repeated.
Obviously this process is not very efficient. The lead time for
the design is long, and the cost is high.

Traditional Product Design and

Development Process

Sequential vs. Concurrent Design

Begin Module 2

Lecture 14

Engineering

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In a highly competitive market, companies are expected

to develop new products frequently.
If the time and cost to develop a new product is too high,
customers may shift to a competitor.
The majority of the life cycle cost of the product is
determined at the design stage. So we need to ensure
that the design is done correctly.
Any mistakes at the design stage are easy to correct.
Mistakes become more expensive, if discovered
downstream.

Why Quality By Design

Quality must be built into the product at the design

stage
Using multidisciplinary teams and simultaneous
engineering
Simultaneously design and develop a product to
ensure producibility and customer satisfaction
Also known as simultaneous or concurrent
engineering

Definition of Quality by Design

Classical Over-the-Wall
Serial Design

Design

Over the Wall Product Development

Approach

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Faster product development.

Better quality.
Less work in progress.
Fewer engineering changes order.
Increased productivity.

Benefits of Quality By Design

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In traditional designs of industrial plants, the building

structure is first designed.
After the building is designed, we figure out how the
utilities will be provided.
After all of the above are complete, we design the
flow of material.
Would it not be better to consider the various
aspects, architecture, civil, electrical, HVAC, and
material flow simultaneously?

Example of Sequential Design

Product Development
Flow Diagram

Teams
Superior Communication
Implementation Plan
IT Tools and Systems Tools

Quality By Design requires the following:

Quality By Design

Teams
Communication

Quality By Design

Begin Module 3

Lecture 14

End of Module 2

Lecture 14

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The team include product developers from marketing,

research and development ,design production, test and
logistics.
Supplier and customer should also be included in the
team.
The implementation of quality by design team requires
top-down commitment.
Team members should be committed to the projects not
with their functional departments.
There should be better communication and interaction
between the team members.

Teams

Product Development Team

From: Kolarik
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Customer Interacts Horizontally with

All Departments/Functions

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An alternative to co-location, is to connect people

by technology. The people in a team are able to
meet and discuss matters virtually.
This gives us the advantages of having the
traditional organization, while forming teams to
work on specific projects.
Some face-to-face meetings may be required.
Overall costs may be reduced in this manner

Alternative to co-location

Virtual Co-Location

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People accustomed to traditional organizational

structure are uncomfortable
Sometimes, designers, etc. work better when
working alongside other designers
Co-location may require duplication of some
functions
Recruitment and development may become more
difficult

Issues with co-location

Co-Location

Co-Location

Communication

Communication

In traditional organizations, the structure is one of

silos.
There is good communication within a silo, but very
poor communication exists across organizational
silos.
If someone in product design needed to talk to
someone in marketing to discuss the impact of a
design change, there are no ready channels for such
communication

Communication

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Whole product cycle

Internal and external customers
Commitment to quality for the entire process
of making the product and not just the
product itself
Co-location, dedicated (to the project) team
members, face-to-face or virtual meetings &
communication

Implementation

Implementation
Tools

Quality By Design

Begin Module 4

Lecture 14

End of Module 3

Lecture 14

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Organizational Tools
Product Development Tools
Production Tools
Statistical Tools

Tools used in Product Design

Organizational Tools
Product Development Tools
Production Tools
Statistical Tools

Tools used in Product Design

Management of Quality by Design requires a basic change in

thinking by management
Functional departments need to have broader thinking
beyond departmental boundaries
It is important to have dedicated project teams
After a team has worked together for a project, it helps to
rotate team members to get fresh perspectives
Even if you use virtual teams, it is important to have face-toface meetings to get people comfortable with each other

Implementation

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Product Development Tools

TQM philosophies
Computer networks
ISO 9000
ISO 14000
Total productive maintenance
Information technology
Electronic meeting software
Enterprise resource planning software

Robotics
Computer numerical controlled tools
Continuous process improvement
Just-in-time production
Virtual manufacturing software
Agile (or lean) manufacturing
Advanced measurement and verification

Production Tools

QFD
Computer-aided drafting software
Solid modeling software
Finite element analysis software
Parametric analysis software
Rapid prototyping techniques
Design for X (manufacture, assembly, service,
environment)
Failure mode and effects analysis

Organizational Tools

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 It is a product planning tool used to fulfill customer

expectations.
It is a disciplined approach to product design,
engineering, and production.
It can improve engineering knowledge, productivity
and quality and reduce costs, product development
time, and engineering changes.
It is employed to translate customer expectations
(voice of the customer) requirements to specific
product requirements in terms of engineering or
technical characteristics.

QFD

Quality Function Deployment

Begin Module 5

Lecture 14

End of Module 4

Lecture 14

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QFD Cascade

House of Quality

QFD
Approach

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 In this lecture we discussed the process of

design
Traditional approaches to design are
sequential. This causes gaps in
communication, resulting in longer product
development cycles and high cost
Quality by design requires simultaneous or
concurrent design and development activities

Summary of Lecture 14

Summary

Begin Module 6

End of Module 5

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End of Module 6

Lecture 14

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We need to form multi-disciplinary teams of

people required in the design process to improve
communication
Ideally the teams should be co-located. However,
virtual teams may also be used.
Quality Function Deployment is a way to convert
the voice of the customer into detailed design
and production and process plans.

Summary of Lecture 14