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Presentation based on excerpts from Product Development Forum by Ken Crow, NPDP, President of DRM Associates, San Diego, CA.
Website URL: http://www.npd-solutions.com/index.html
AdvancedProductQualityPlanning
The APQP process is described in AIAG manual 810358-3003. Its purpose is "to produce a product quality plan which will support development of a product or service that will satisfy the customer." It does this by focusing on: Up-front quality planning Evaluating the output to determine if customers are satisfied & support continual improvement.
AdvancedProductQualityPlanning
The Advanced Product Quality Planning process consists of four phases and five major activities along with ongoing feedback assessment and corrective action.
AdvancedProductQualityPlanning
ProcessOutputs
Value Engineering
Design Reviews
Design reviews . Design reviews are formal reviews conducted during the development of a product to assure that the requirements, concept, product or process satisfies the requirements of that stage of development, the issues are understood, the risks are being managed, and there is a good business case for development. Typical design reviews include: requirements review, concept/preliminary design review, final design review, and a production readiness/launch review. Value Engineering can also be included in the design review process to validate the design and reduce cost.
Controlspecial/criticalcharacteristics
Control special/critical characteristics. Special/critical characteristics are identified through quality function deployment or other similar structured method. Once these characteristics are understood, and there is an assessment that the process is capable of meeting these characteristics (and their tolerances), the process must be controlled. A control plan is prepared to indicate how this will be achieved. Control Plans provide a written description of systems used in minimizing product and process variation including equipment, equipment set-up, processing, tooling, fixtures, material, preventative maintenance and methods
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CustomerFocusedDevelopment withQFD
Quality must be designed into the product, not inspected into it. Quality can be defined as meeting customer needs and providing superior value. This focus on satisfying the customer's needs places an emphasis on techniques such as Quality Function Deployment to help understand those needs and plan a product to provide superior value
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CapturingtheVoiceofthe CustomerwithQFD
Quality Function Deployment (QFD) is a structured approach to defining customer needs or requirements and translating them into specific plans to produce products to meet those needs. The "voice of the customer" is the term to describe these stated and unstated customer needs or requirements.
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CapturingTheVoiceOfThe Customer
The process of capturing the voice of the customer is described in the papers on Product Definition and Steps for Performing QFD. It is important to remember that there is no one monolithic voice of the customer. Customer voices are diverse. In consumer markets, there are a variety of different needs. Even within one buying unit, there are multiple customer voices (e.g., children versus parents). There are even multiple customer voices within a single organization: the voice of the procuring organization, the voice of the user, and the voice of the supporting or maintenance organization.
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CapturingTheVoiceOfTheCustomer
Quality Function Deployment requires that the basic customer needs are identified. Frequently, customers will try to express their needs in terms of "how" the need can be satisfied and not in terms of "what" the need is. This limits consideration of development alternatives. Development and marketing personnel should ask "why" until they truly understand what the root need is. Breakdown general requirements into more specific requirements by probing what is needed
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Once customer needs are identified, preparation of the product planning matrix or "house of quality" can begin. Customer needs or requirements are stated on the left side of the matrix These are organized by category based on the affinity diagrams.
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Step 7 - Interactions
Determine potential positive and negative interactions between product requirements or technical characteristics using symbols for strong or medium, positive or negative relationships. Too many positive interactions suggest potential redundancy in "the critical few" product requirements or technical characteristics. Focus on negative interactions - consider product concepts or technology to overcome these potential tradeoff's or consider the tradeoff's in establishing target values.
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QFD Summary
Product plan is developed based on initial market research or requirements definition. If necessary, feasibility studies or research and development are undertaken to determine the feasibility of the product concept. Product requirements or technical characteristics are defined through the matrix. A business justification is prepared and approved, and product design then commences.
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ConceptSelectionAndProductDesign
Once product planning is complete, a more complete specification may be prepared. The product requirements or technical characteristics and the product specification serve as the basis for developing product concepts. Product benchmarking, brainstorming, and research and development are sources for new product concepts. Once concepts are developed, they are analyzed and evaluated. Cost studies and trade studies are performed. Use the concept selection matrix to help with this evaluation process
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Concept Evaluation
The product requirements, or technical criteria serve as evaluation criteria (just like in VE). The importance rating and target values (not shown) are also carried forward and normalized from the product planning matrix. Product concepts are listed across the top. The various product concepts are evaluated on how well they satisfy each criteria in the left column using the QFD symbols for strong, moderate or weak. If the product concept does not satisfy the criteria, the column is left blank.
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Concept Evaluation
The symbol weights (5-3-1) are multiplied by the importance rating for each criteria. These weighted factors are then added for each column. The preferred concept will have the highest total. This concept selection technique is also a design synthesis technique. For each blank or weak symbol in the preferred concept's column, other concept approaches with strong or moderate symbols for that criteria are reviewed to see if a new approach can be synthesized by borrowing part of another concept approach to improve on the preferred approach.
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Concept Selection
Based on this and other evaluation steps, a product concept is selected. The product concept is represented with block diagrams or a design layout. Critical subsystems, modules or parts are identified from the layout. Criticality is determined in terms of effect on performance, reliability, and quality. Techniques such as fault tree analysis (see book) or failure modes and effects analysis (FMEA) (see book) can be used to determine criticality from a reliability or quality perspective.
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A powerful analysis method is created when FAST is used in conjunction with QFD. QFD enables the uses of the Value Analysis Matrix. An example of a value analysis matrix for the pencil example is shown next.
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Part II
Introduction to Failure Modes and Effects Analysis
From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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WHY?
W H E N
CONVEY Information
PROJECT IMAGE
GENERATE LIGHT
RECEIVE CURRENT
TRANSMIT CURRENT
(concept)
DISSIPATE HEAT
AMPLIFY IMAGE
GENERATE NOISE 52
The diagram shows the logical relationships of components and activities [Functions] and establishes a structure around which the FMEA can be developed. Identify Failure Modes. A failure mode is defined as the manner in which a component, subsystem, system, process, etc. could potentially fail [or has failed] to meet the design intent. A failure mode in one component can serve as the cause of a failure mode in another component. [This is a basic premise of FAST] Failure modes should be listed for function of each component or process step. At this point the failure mode should be identified whether or not the failure is likely to occur.
From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
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http://www.npd-solutions.com/fmea.html
Possible Effects
Injury to the user Inoperability of the product or process Improper appearance of the product or process Odors Degraded performance Noise
From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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Possible Causes
Improper torque applied Improper operating conditions Contamination Erroneous algorithms Improper alignment Excessive loading Excessive voltage
From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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From: Failure Modes and Effects Analysis(FMEA), by Kenneth Crow, DRM Associates
http://www.npd-solutions.com/fmea.html
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WHY
Follow Inspection Plan Establish Integrity Criteria Define Container Integrity Write Inspection Plan Verify Inspection Plan Develop Inspection Plan Validate Inspection Plan INPUT
Determine Condition
Inspect Container
WHEN
Determine Disposition
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Incorrect Container ID Incorrect Contents Inaccurate Determination Deterioration After Inspection/Damage After Inspection Inadequate Procedures Inadequate Equipment False Positive Reading for Excessive Thinning Inadequate Training [Poor] Human Factors [Interface] - Ability to see contents, position
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Management Pressure to Perform Inadequate Quality Checks Inadequate Inspection Criteria Subjective Inspection Criteria Poor Container Condition hampers inspection Time - Availability - 5 min./drum, 1 min. for inspection Poor Weather/Environment al Conditions - Human Factors
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Inadequate Procedures Results Not Tested/Verified Writer of Procedure is not familiar with process Vague Text Inadequate Training Trainers have not had direct experience with the inspection process. Inadequate Training Materials: Poor Illustrations Field Examples Poor Materials not definitive enough
Inadequate Inspection Criteria Too vague Driven by Management Goals Unclear goals and objectives available for development of criteria. Too little quantitative measures and performance parameters. Condition could not be assessed. No measurement of wall thickness... etc. Figure 3
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Summary
Value Engineering is a powerful, interdisciplinary problem solving tool. VE is used to improve cost, and performance without sacrificing quality. In fact, VE can be used to improve quality. FMEA applied to FAST greatly enhances VEs ability to improve quality in existing products, process, or services FMEA applied to FAST can also improve new product development
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