MPD 575 DESIGN FOR QUALITY

Developed By:
Sam Abihana Ion Furtuna Adithya Rajagopal

INTRODUCTION
Definition of Quality What is DFQ How DFQ fits into the Ford PD process DFQ Process Flow Example of DFQ Applied to the Seat System

DEFINITION OF QUALITY

The Customer defines Quality Our customers want products and services that throughout their lives meet their needs and expectations at a cost that represents value Ford Quality Policy
Fitness for use (Fitness is defined by the customer) J.M. Juran The totality of characteristics of an entity that bear on its ability to satisfy stated and implied needs ISO 8402 The loss a product imposes on society after it is shipped Taguchi A subjective term for which each person has his or her own definition American Society for Quality

DESIGN FOR QUALITY (DFQ)

Quality is intrinsic to a design and is dependent on:

Choice of system architecture Robustness of execution during the PD process

Quality is primarily associated with two aspects i.e. functional performance and customer perception DFQ is the disciplined application of engineering tools and concepts with the goal of achieving robust design development and definition in the PD process The DFQ process allows the engineer to: identify, plan-for and manage factors that impact system robustness and reliability upfront in the design process

DESIGN FOR QUALITY (DFQ)

Common product design tools associated with DFQ, and discussed in this presentation, are:

Boundary Diagrams Interface Matrix Parameter Diagram (P-Diagram) Design Failure Mode and Effects Analysis (DFMEA) Reliability Checklist (RCL) Reliability Demonstration Matrix (RDM) Design Verification Plan (DVP)

The engineering concepts associated with the tools identified above are based on proven methods which can be applied across a variety of industries

DFQ IN THE FORD PD PROCESS (GPDS)

PHASES IN UNDERBODY DEVELOPMENT
UN V0 UN V1 UN V2 M1DJ

PHASES IN UPPERBODY DEVELOPMENT

UP V0 UP V1 UP V2 FDJ

UN V0/UP V0: Boundary Diagram/Interface Analysis/P-Diagram/DFMEA/RDM/RCL initiated. Quality History review and documentation completed UN V1/UP V1: Boundary Diagram/Interface Analysis/P-Diagram/DFMEA/RDM/RCL updated UN V2/UP V2: Disciplines completed, DFMEA updated with recommend actions M1DJ: Under Body Engineering Freeze/Signoff FDJ: Upper Body Engineering Freeze/Signoff

DFQ PROCESS FLOW

PRODUCT DESIGN

BOUNDARY DIAGRAM

INTERFACE MATRIX

P-DIAGRAM

DFMEA

RELIABILITY CHECKLIST

ROBUSTNESS DEMONSTRATION MATRIX

DVP

PROCESS DESIGN

PFMEA

CONTROL PLAN

BOUNDARY DIAGRAM
What?

Defines the scope of the system being studied Identifies components that are internal to the system Identifies system-system, system-human and systemenvironment interfaces (External Components) Defines the scope of the DFMEA i.e. elements within the boundary Indicates the nature of all interface relationships Represents all of the above in a clear graphical manner

BOUNDARY DIAGRAM
Why? Provide a disciplined approach to ensuring all system interfaces are considered at design initiation Understand the nature of interface relationships i.e.

Physically touching (P) Energy transfer (E) Information transfer (I) Material exchange (M)

Communication tool which facilitates team understanding and collaboration

BOUNDARY DIAGRAM
How? Identify components within the system as blocks Establish relationships between the various blocks Establish relationships between system components and other systems, including customer input Construct a boundary line around what is best included within the analysis of the system Boundary diagram analysis should follow system hierarchy down to the desired sub-system, component level

SEAT SYSTEM BOUNDARY DIAGRAM

Door Trim Panel Floor Pan P.2.1+E Wiring Harness (Vehicle) P.5+E

Seat Cushion Asy

P.5+E

Cushion Pan Asy

P.2.2+E

Track Asy

P.4+E

P.2.1+E

P.2.1+E

Recliners P.8+E P.4+E OCCUPANT P.5+E Seat Back Cushion Asy

P.4+E

Seat Buckle Asy

Back Frame Asy P.8+E

P.6+E

Lumbar Asy

P.8 P.5+E

Head Restraint Assembly

BOUNDARY DIAGRAM LEGEND

Relative Motion Clearance No Motion Occupant Interaction

Sub Assembly Boundary of Analysis Internal Component Directed or External Component

P P.1 P.2.1 P.2.2 P.2.3

Physically touching Adhesive Fastener - Bolt Fastener - Screw Fastener - Rivet

P.3 P.4 P.5 P.6 P.7

Sewing Rotational Snap Fit Weld Crimp (Hog ring, )

P.8 E I M

Interfacing not joined Energy Transfer Information exchange Material exchange

INTERFACE MATRIX
What?

Provides a supplemental analysis of the boundary diagram Quantifies the strength of system interactions Provides input to the Potential Effects of Failure and Severity column of the DFMEA Robustness linkage to the P-Diagram

Why?

Positive interactions may be captured on the P-Diagram as input signals or output functions Negative interactions may be captured on the P-Diagram as input noise or error states

Cross-check boundary diagram interfaces Verify positive interactions Manage negative interactions for robustness

INTERFACE MATRIX
How?

List all elements within the boundary diagram and all elements that interface across the boundary in the left most column of the Interface Matrix sheet Fill the 4 quadrants (Q1-Q4) representing the interface relationship (P, E, M, I) between the elements of the Boundary Diagram with a rating from -2 to +2
2 1 0 -1 -2 = = = = = Necessary for function Beneficial but not absolutely necessary for function Does not affect functionality Causes negative effects but does not affect functionality Must be prevented to achieve functionality

SEAT BACK CSHN ASY

SEAT BUCKLE ASY

WARNING!!!! Do not enter values into the grayed out area. Only enter areas into the white area. When values are entered into the white area, the corresponding gray side will automatically be entered. OCCUPANT DOOR TRIM PNL FLOOR PAN WIRING HARNESS SEAT CSHN ASY RECLINERS SEAT BACK CSHN ASY HEAD RESTRAINT ASY CSHN PAN ASY BACK FRAME ASY TRACK ASY SEAT BUCKLE ASY LUMBAR ASY 0 0 0 0 0 0 2

HEAD RESTRAINT ASY

BACK FRAME ASY

WIRING HARNESS

SEAT CSHN ASY

DOOR TRIM PNL

CSHN PAN ASY

0 0 P E 0 M I 0 0 0 0 0 0 0 2 0 2 0 2 0 2 0 0 0 0 0 0 0 2 0 0 0

0 0 0 0

0 0 0 0

0 0 0 0 0 0 0 -2 0 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0

0 0 0 0 0 0

0 2 2 0 2 0 0 0 0 0 0 -2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 -1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 2 2 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

2 0 -2 0 0 0 0 0 -1 0 0 0

2 0 0 0 0 0 0 0 0 0 0 0

2 0 0 0 0 0 0 0 0 0 0 0 0

2 0 0 0 0 0 0 0 0 0 0 0 0

0 0 0 0 0 0 0 0 0 2 0 0 0 0 0

0 0 0 0 0 0 0 0 0 2 0 0 0 0 0

0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 2 0

0 0 0 0 0 0 0 0 0 0 0 2 0 2 0 2 0

0 0 0 0 2 0 2 0 0 0 0 0 0 0 0 2 0 2 0

0 0 0 0 2 0 2 0 0 0 0 0 0 0 0 2 0 2 0

-1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0

2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0

0 0 0 0 0 0 0 0 0 0 0 -1 0 0 0 0 0 2 0 0 0 0 0

LUMBAR ASY

FLOOR PAN

RECLINERS

TRACK ASY

OCCUPANT

0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0 2 0 0 0 0 0

-2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2 0 0 0 0 0

0 0 2 2 0 0 0 0 0 0 0 0

0 0 0 2 0 2 0 0 0 0 0 0 0 -1 0 0 0

0 0 0 0 2 0 0 0 0 0 -1 0

0 0 0 0 2 0 0 0 0 0 2 0

0 0 2 0 0 0 0 0 0 0

0 0 2 0 0 0 0 0 0 0

2 0 2 0 0 0 0 0

2 0 2 0 0 0 0 0

2 0 0 0 2 0

2 0 0 0 2 0

2 0 0 0

2 0 0 0 0 0 0 0

P-DIAGRAM
What?

A graphical tool to identify the operating environment in robustness focused analysis Provides a structured method to identify:

Intended Inputs (Signals) Intended Outputs (Ideal Function) Unintended Inputs (Noise Factors) Unintended Outputs (Error States) Design Controllable Factors

P-DIAGRAM
What?
Noise factors are classified as: Demand related noise which are external to the design

Piece-to-Piece Variation (N1) Changes Over Time (N2) Customer Usage (N3) External Environment (N4) System Interactions (N5)

Capacity related noises which are internal to the design

P-DIAGRAM Why?

Brainstorming tool that supports downstream noise factor management strategies (RCL) and verification methods (RDM/DV) Links to the Function, Potential Failure Mode and Potential Effect of Failure columns of the DFMEA

P-DIAGRAM
How?

P-Diagrams should support the scope of the system defined in the Boundary Diagram Input & Output Signals: Identified in terms of physics as positive interactions in the Interface Matrix Noise Factors (N1-N5) & Error States: Identified in terms of physics as negative interactions in the Interface Matrix. Brainstorming should be applied to supplement identification of Noise Factors Error States: Undesired function. Quality History should be used to supplement identification of error states Control Factors: List of design factors that can be controlled in design i.e. materials, dimensions, location etc.

SEAT SYSTEM P-DIAGRAM

N1 Piece to Piece N2 Change over Time N3 Customer Usage N4 External Environment N5 System Interaction

a) Variation in foam ILD (+/- 15% N) b) Seath width (+/- mm)

a) Occupant weight (lbs)

Noise Factors Input Signal

OCCUPANT - CUSH ASY a) Occupant jounce load of 50th percentile male butt form loaded to 200 lbs b) Seat wideline packaging zone (Y-Plane coordinates)

Ideal Function Output

a) Driver cushion must pass 200,000 jounce cycles perpendicular to the cushion at 90cpm with sag <25mm b) Seat width must be within the packagaing zones (mm)

1st Row Seat Asy

Control Factors
a) Nominal density and ILD of foam (330N, 50 kg/m3) b)Seat design width (mm)

Error States
a) Sag >25mm after speified cycles DR TRIM PANEL - CUSH ASY b) Toleranced seat width exceeds packaging zone reqmts (mm)

DFMEA
What? A tool which supports activities that recognize and evaluate potential failure modes of a product and its effects Identifies actions which could reduce or eliminate the chances of the failure occurring Documents the analysis process

DFMEA
Why? Improve the quality of product evaluation by applying a standardized method Determine how failure modes will be avoided in design Allows the engineer to recognize high priority/high impact failure modes and prevent them from occurring Improve the robustness of the DVP and process control plans

DFMEA: ROBUSTNESS LINKAGES

P-Diagram Linkage Boundary Diagram Linkage Interface Matrix Linkage

DFMEA: HOW?

SEAT SYSTEM: DFMEA

SEAT CUSHION Support 200K jounce cycles (90cpm) of 50th percentile male butt form loaded to 200lbs with seat sag <25mm

Seat sag >25mm

Poor appearance 5 Customer discomfort

Inadequate foam density and ILD

D: DV Jounce Testing

2 30

ROBUSTNESS CHECKLIST (RCL)

What? Captures noise factors and error states identified in the P-Diagram

Identifies areas that require design based noise factor management strategies
Indicates verification methods which provide the ability to test for the error states associated with the noise factors

ROBUSTNESS CHECKLIST (RCL)

Why? Initiate team discussion regarding noise factor management strategy (NFMS) and robust verification

Focus on noise factors which have the highest impact on system robustness
Understand the correlation between the error states and associated noise factors Assist robust verification by identifying noise factors which are currently not captured by existing DVMs

ROBUSTNESS CHECKLIST (RCL)

RCL: HOW?
IDEAL FUNCTIONS VERIFICATION METHODS

Step 1: Choose ideal functions

USEFUL LIFE PERIOD

ERROR STATES

Interaction/Test Method Strong = Weak = None = | VM Types B - Bogey D - Degradation F - Failure

Step 7: List

HIGH IMPACT

applicable
DVMs

10 years and/or 150,000 miles [3600 life cyles]

VM TYPE

ERROR STATES
I H G F E D C B A
A E F G H I

NOISE FACTOR MANAGEMENT STRATEGY (NFMS)

Cat
I II III IV V VI

I H

Step 8: Use an X show error states identified DVM. Identify Impact DVMs
HIGH IMPACT

G to F E D

Step 2: Choose focused error states

B

D C

Metric

Range
A B C D E F G H I

Strategy Change Technology Apply Parameter Design Upgrade Design Spec. Reduce / Remove Noise Add Compensation Device Disguise / Divert NFMS Descriptions

C by

B High A

Step 3: List associated noise factors

NOISE 1: Piece to Piece Variation NOISE 2: Change Over Time NOISE 3: Customer Usage NOISE 4: External Environment NOISE 5: System Interaction

Step 4: Define metric and range for each noise factor Step 5: Assess strength of correlation between error state and noise factor

Step 6: Define NFMS Step 9: Use an X

to show
noise factors included in the DVM

SEAT SYSTEM: RCL

IDEAL FUNCTIONS
Must complete 200K (90 cpm) jounce cycles of 50% male butt form loaded to 200lbs with sag <25mm

Seat System Jounce Durability

1

VERIFICATION METHODS
2 3 4 5

USEFUL LIFE PERIOD

HIGH IMPACT

10 years and/or 150,000 miles [3600 life cyles]

VM Types B - Bogey D - Degradation F - Failure

Drive Durability
D

Strong = Weak = None = |

ERROR STATES

Interaction/Test Method

VM TYPE

ERROR STATES
I H G F E D C B A
B C D E F G H I

NOISE FACTOR MANAGEMENT STRATEGY (NFMS)

Cat I II III IV V VI

I H G F E D C B A

Sag >25mm within 200K jounce cycles Metric Range

Strategy Change Technology Apply Parameter Design Upgrade Design Spec. Reduce / Remove Noise Add Compensation Device Disguise / Divert NFMS Descriptions

X X X

HIGH IMPACT

A B C D E F

G H I

NOISE 1: Piece to Piece Variation

Variation in foam density kg/m3 45-55 III Increase foam density

NOISE 2: Change Over Time NOISE 3: Customer Usage

Occupant weight (95th percentile) lbs 150-215 III Increase foam ILD (N) X

NOISE 4: External Environment NOISE 5: System Interaction

RDM/DVP
What? Planning tool that documents:

Design Verification Methods (DVM) Level Tested Acceptance Criteria Test Timing

RDM is a subset of the DVP that additionally documents:

Failure Mode (Hard or Soft) DVM for select tests specified by the RCL Noise Factors being tested Robustness targets in relation to customer expected function. Targets of R/C (R90/C90) are not acceptable

RDM/DVP
Why?

Demonstrates that components/systems fulfill reliability requirements identified in the RCL Provides a forum to review the high impact error states and noise factors that affect the system along with the identified DVM to prove out their system Structured documentation of verification test plans and timing Provides single point summary of test plans

RDM: HOW?
FROM RCL

VM Description VM Target High Impact Error Description

DVM: Seat Jounce Sag <25mm Durability Sag >25mm

High Impact Noise factors

VM #

Metric Range Demonstrated Result

45-55

Risk (R/YG)

Issues Comp. Date

1 Variation in foam density kg/m3

DVP: HOW?
DESIGN VERIFICATION PLAN
Program Part Name Item # Test Name/Source Supplier Part Number Acceptance Criteria Test Results (incl. Pass/Fail) (Ref. Test Report #) Product Development Engineer Product Development Manager Design Sample Size Level Tested Required Tested Start Timing Sched. Actual STA Engineer Chief Program Engineer Completion Remarks Timing Sched. Actual

Date revised:

Seat Cushion: Jounce the seat at 90 cycles per minute + /10%, perpendicular to the CP of the seating surface with a 50% male size butt form loaded to 900 N (200 lb) as defined in DVM-0036-ST v9. Cushion samples to be tested at 45 and 55 kg/m3 densities per RDM.

Sag <25mm after completion of 200K jounce cycles on 3 consecutive samples

DV

1/1/2007