Transcript Sauer-Danfoss

Special Characteristics Training
GS0400
powersolutions.danfoss.com
Danfoss Power Solutions
TR-0024 Special Characteristics Training for GS-0004
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Academy special characteristics class
- Course options
Course
Length
Awareness
Competency
Mastery
2 hour
4 Hours
8 Hours
•What are they?
•Why have them?
•How Do They Fit in to
PPAP & PDLP?
•Who is Responsible?
•How do I find them on
drawings/Specs?
Awareness +
•How to Determine
special
characteristics
•GRR, Capability,
SPC requirements
•FAQ
Competency +
•Loss Functions
•S x O = Loss Function
•Role of Control Plan,
GRR, Capability for
different loss functions
•Making Good Decision
Team Leaders
Supervisors
Design/Process Ldrs
Quality/Design/Process Eng
Purchasing
Incoming Inspection
Quality Techs
Supplier Quality
Incoming Inspection
All Quality Eng.
Some Design Eng.
Some Process Eng.
Supplier Dev.
DFMEA facilitators
Learning
Use Controls at Lower Left
To select Training level
(Must be in Presentation Mode)
Roles
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Product Test
GS0017
PPAP
GS0008
Steps to Quality
ISIR
GS0015
Control Plan
GS0012
Capability
GS0007
Gage R&R
GS0010
P-FMEA
GS0006
Process Map
GS-0063
Special Char.
GS0004
D-FMEA
GS0003
QFD
3
GS0031
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Agenda
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What GS-0004 Covers
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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What is the purpose of special characteristics?
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Focus Special Attention on the “Vital Few” Things which make a
Difference to our Customers
Formally Communicate these “Vital Few” Characteristics and their
Required Process Controls throughout the Supply Chain
Promote Design For Manufacturability (DFM) through Simultaneous
Discussions regarding Design Tolerances and Manufacturing Variation
Aid in Economically Manufacturing Quality Products that meet Customer
Expectations
Require Greater Production Control/Monitoring of the “Vital Few”
Facilitate Knowledge Management through time (both Product
Engineering & Process Engineering)
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What does “Special Attention” mean?
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Focused Attention during the Design and Processing
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Drives Severities from DFMEA into PFMEA
Required Levels of Process Capability and Control
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Data based Design For Manufacturability (DFM)
Gage R&R, Capability exceeds
Features included on Control Plan with appropriate Statistical Controls
Indicate importance of the features throughout the life of the
product/process (Knowledge Management)
Ensure Extra attention is made during review of PPAP/Change
Management document review
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“Vital Few”
Aren’t they All important?!
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Yes – All we must strive for all features to always be “In Print”
Key Characteristics are those characteristics that being “On target with
Minimum Variation” provides better satisfaction than just being “in Print”
Features not important for customer safety or satisfaction can be
handled differently for more economical manufacturing
Focusing on All is like Focusing on None!
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Why “Vital Few”?
How many should we have?
Lets look at the Loss Function
“Loss”
Total Product
Dis-Satisfaction
Dis-Satisfaction
Due to Cost
Performance
Dis-satisfaction
0
Number of
Special Characteristics
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TR-0024 Special Characteristics Training for GS-0004
All
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Agenda
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GS-0004
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Scope & Application
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GS-0004 Creates Special Characteristics
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GS-0004 applies to
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Safety Characteristics
Key Characteristics
Process Characteristics
Standard Characteristics
Danfoss Power Solutions Globally
All New Designs
GS-0004 Defines
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Selection
Identification
Documentation
Required Manufacturing Controls
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Agenda
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GS-0004
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Definition
Safety Characteristics
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Safety characteristics are those characteristics/features which have the
potential to affect safety.
When defining safety characteristics the safety of all personnel involved in
the product test, vehicle commissioning, and end use of the product need to
be considered.
Safety characteristics should be controlled through
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robust safety margin for normally expected process variation
AND
manufacturing error-proofs that detect/prevent abnormal process variation which
could significantly reduce safety margin.
Safety characteristics will be identified on the engineering drawing with a
pentagon with an ‘S’ inside it.
S
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Definitions
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Normally expected process variation
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The amount of manufacturing variation when the process is maintained under
the defined process controls.
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Safety margin
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The difference between the extreme of normally expected process variation and
the point at which a safety loss could occur
Abnormal process variation
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Unusual Manufacturing variation created by a process failure
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Note that for some process controls normally expected variation will include
some out of specification
Broken tool, missed heat treatment, etc
Error-proof
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Device or method which Detects and contains/corrects abnormal variation
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Definitions- safety margin
Lower
Specification
Limit
Point at which
Safety is Impacted
Upper
Specification
Limit
Design
Specification
Safety Margin
Normally Expected
Process Variation
Abnormal
Process Variation
Examples
Note: Normally Expected Process Variation Shown is for a process with 100% Sort and a GRR of 50%
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Definition
Key characteristics
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Key characteristics are defined to be those characteristics for which the
normally expected process variation affects product function/customer
satisfaction
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Customer can distinguish product differences due to the variation of a key
characteristic within specification
Customer satisfaction is increased when these characteristics are
maintained on target with minimum variation
Key Characteristics will be identified on the engineering drawing with a
pentagon with a ‘K’ inside it
K
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Definition
Process characteristics
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Process Characteristics are features/characteristics which do not directly
affect the function of a product but are important for success of
downstream manufacturing processes
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Tolerances held tighter than needed for product function to accommodate robotic
assembly
Internal Customer satisfaction depends on these features being
in specification
External Customer Satisfaction (Product Function) does not require the
tolerance to be held this tightly
Process characteristics will be identified on the engineering drawing
with a pentagon with a ‘P’ inside it
P
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Q: Why did we create a Process Characteristic
A: Some areas do automated assembly. For automated assembly you often
have a robot grabbing the part on a non-functional area and then
assembling into a tight clearance
Robot Grabs d2 and installs
spool into bore
If Concentricity (
) of d2 to D1 is not
important for function but is necessary for
Automated assembly. Concentricity of d2
to D1 would be a Process Characteristic
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Process Characteristic Example
Endcap
A-B machining operation in a cell
bolt holes Machined in A-op and used for location on the B-op.
For the process we need to the holes to be
+ .1 and a True Position of .1mm
Engineering Drawing (Function) says
+.13mm and True Position of .75mm
Should we Modify the Engineering Drawing and Use a P?
No – If it is within your own processes it should be done within your own
process controls (e.g. cell control plan/process drawings, etc)
Not with the Engineering Drawing
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Definition
Standard characteristics
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The majority of features in a good design are standard features.
Standard features must be maintained within specified limits
Standard Features are those for which reasonably anticipated
manufacturing variation is unlikely to significantly affect a product’s
safety or function
Customer satisfaction does not change based on where a standard
feature is within its tolerance range
Standard Features do not have a symbol
No
Symbol
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Agenda

GS-0004
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Responsibility
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Product Engineering is responsible for identifying and classifying
Safety and Key special characteristics as soon as practical in the design
process
Product Engineering Managers in individual areas shall be
responsible for ensuring Special characteristics are correctly
documented on Engineering drawings and specifications
Process characteristics, if required, are to be identified by Process
Engineering
Operations and Purchasing Managers in individual areas shall be
responsible for ensuring adequate process controls are put in
place for special characteristics
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Assigning special characteristics
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Design Engineering Assigns Safety and Key Characteristics Utilizing the
Design FMEA as soon as possible in the Design Process
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Safety Characteristics
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Key Characteristics
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Severity ≥ 5 & Occurrence ≥4
Safety and Key Characteristics
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Severity ≥ 9
Severity ≥ 9 & Occurrence ≥4
Manufacturing Engineering Assigns Process Characteristics
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Assigning Safety Characteristics
Within propel
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Assignment of Safety Characteristics Requires Special Controls
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Follow your local BA rules (usually requiring Director of Engineering
Approval) before assigning Safety characteristics to drawings.
S
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Agenda

GS-0004
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Determining Special Characteristics
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First Use Design FMEA
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Severity and Occurrence Ratings
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Special Characteristics Table
Then Evaluate “Border” cases using Loss Function Method
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Continuous or Step Loss
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No Margin, Small Margin, Large Margin
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“Border Cases” from Severity and Occurrence Table
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Covered in “Expert” Training
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Determining Special Characteristics
Using DFMEA Severity & Occurrence (S x O)
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DFMEA Severity
Reference GS-0002/HPP 200
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DFMEA Occurrence
Reference GS-0002
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Applying Judgement
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In addition to the use of DFMEA Severity and Occurrence, Key
characteristics can be determined using the quality loss function logic
defined in Appendix ‘C’ of GS0004
Quality Loss Function logic can be an effective way to assess “border”
cases from the “S x O” method (i.e. Occurrences of 4,5 & 6 and
Severities of 5 and 6) to determine if classification as a “Key”
characteristic is really warranted
Engage an expert in Quality Loss functions
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DFMEA facilitators
Quality Engineers
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Determining Special Characteristics
Using DFMEA Severity & Occurrence (S x O)
Border Cases
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Special Characteristics Applied to
Material or Heat Treatment Specs
Special Characteristics may be applied to material and heat treatment
specifications
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Key if DFMEA severity ≥ 5 and occurrence ≥ 4
DO NOT base occurrence (design margins) on an assumption of the
supplier using the wrong material or a required heat treatment is omitted
 For example: The part will break if the supplier uses the wrong material so I
will make it a Key Characteristic

Loss Function Method is a very good for material and heat treatment
Specifications.
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Special Characteristics Identified on
Material or Heat Treatment Specs
Material: ASTM A536 Grade 65-45-12
Hardness: 156-217 BHN

The special characteristic must be assigned to something that is
measurable (hardness, case depth, tensile strength, etc.) and not to the
entire specification
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Agenda

GS-0004
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Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Special Characteristics identified on
Danfoss Power Solutions engineering drawings

A pentagon with an “S” for Safety, a pentagon with a “K” for key, or a
pentagon with a “P” for process shall be placed on the technical
document by each characteristic designated as a special characteristic.
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Special Characteristics identified on
Danfoss Power Solutions engineering drawings

In the case that a feature is described by multiple callouts a special
characteristic designation is required for each callout.
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Special Characteristics identified on
Danfoss Power Solutions engineering drawings

In cases where a characteristic is both a safety and a key the special
characteristics are to be designated as shown in Fig 3. The order (K first
or S first) is not important
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Documentation
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Add the Note “Special Characteristics per GS-0004” on the first page of
the Drawing/Specification
Customer Importance Table (CIT) must be on First Page of all
drawings and relevant specifications
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Typical drawing formats shown Below
May be included on other pages
Error-Proof
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Special Characteristics
Location x QTY
Sheet #
Location Table
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An Optional Location Table on Sheet 1 defines where
special Characteristics are Located
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Helpful to make sure that none are missed
This drawing has 36 Specials Located on 5 Sheets
38
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Correctly Showing a Completed Drawing
which has no Special Characteristics
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Add the CIT Table to the First Page of the Drawing/Specification even if
there are no Special Characteristics
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Add the Note “Special Characteristics per GS-0004” on the first page of
the Drawing/Specification

Add the CIT Table and a Blank Special Characteristics Table to the first
page of the Drawing/Specification
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Agenda

GS-0004
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
Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings Created Before GS-0004E
Summary/Q&A
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Process Requirements
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S, K, &/or P characteristics Must be Identified on PFMEA and
Control/Gauging Plan including control method
S Requires Error Proof Control method
K Requires Statistical Control Method
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Therefore statistical Gage R&R and Capability studies must be completed and
exceed minimum requirements
P Does not require a specific control method
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Production control methods
Acceptable for safety characteristics
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The Manufacturing Focus for Safety Characteristics is to ensure that
abnormal variation (i.e. “Special Cause” process failures ) that
significantly reduce or eliminate an adequate design margin do not occur
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What is a abnormal variation
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Process Goes out of control and produces “unexpected” variation
S
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Definitions- Safety margin
Point at which
Safety is Impacted
Lower
Specification
Limit
Upper
Specification
Limit
Design
Specification
Safety Margin
Normally Expected
Process Variation
Abnormal
Process Variation
Note: Normally Expected Process Variation Shown is for a process with 100% Sort and a GRR of 50%
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Example Special causes
(Sources of unexpected variation/Abnormal process variation)
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Wrong Material/Heat treatment
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Wrong raw material received / selected
Wrong or interrupted heat treatment
Doesn’t get to proper temp due to thermal capacitance
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Wrong off-set entered in machine
Wrong insert
Wrong Radii
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Bent dowel pins
Missing rest pads
Tool Set-up Errors
Broken Tools/Wrong Tools
Broken Fixtures
Note that special cause failures affect all
Parts until corrected.
They can create a BIG problem but they
are easier to detect because all parts
are affected
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Example special causes
(Sources of unexpected variation)
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Missed Operations
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Unplanned process stoppages
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Missed heat treat altogether
Missed test / adjustment process
Delay prior to quench
Incomplete operations
Machine restart in middle of program
Undetected Maintenance Issues
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Broken Valves
Furnace Filters
Note that special cause failures affect all
parts until corrected.
They can create a BIG problem but they
are easier to detect because all parts
are affected
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Suitable control plans for
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Safety characteristics require an Error proof
What is an Error proof?
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A process or device that ensures either
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Special cause errors do not take place or
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If it has occurred, does not allow the next process step to take place or
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Produces an immediate error signal and corresponding non-conforming
material control in the event of a special cause errors
What does an error proof Not do

It is not intended to control common cause (normally expected) variation
S
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Establishing good error proofs
1.
Understand the ways the process could fail and produce
Abnormal variation
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2.
Fishbone diagram (5M/E)
PFMEA
Second determine best way to control

Error proof types
 Type 1 Error-Proof: Prevent from happening
 Type 2 Error-Proof: Detect before passing from operation
 Type 3 Error-Proof: Detect at next (or Downstream) operation
S
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Example error proof control methods
(100% Preventing or detecting unexpected variation)
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Wrong material
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Bars: Each bar verified as loaded in machine properties or color code
Castings: Lot material certifications
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Samples inspected from each lot
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Inspection at next operation
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Inspect 1st piece/last piece
Broken tool Detection (Laser or Load Monitoring)
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Inspect 1st piece
Barcode at pre-setter/scan at installation
Tool holder only accepts correct insert

IR temperature reading at quench
Wrong or inadequate heat treatment
Missing heat treatment
Broken tools
Wrong tool/wrong insert/wrong offset
Delay before quench
Danfoss Power Solutions
TR-0024 Special Characteristics Training for GS-0004
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Process control requirements
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Safety Characteristics
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/
PPAP Requirements
Identified as safety on PFMEA & assigned severity = 10
Identified as safety on Control plan with an error proof (Poke-Yoke)
documented on control plan
S
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Process control requirements
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Key characteristic / PPAP requirements
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Identified as “Key” on PFMEA & Assigned severity = 8
Production control with variable gauging & GR&R<20% completed per GS-0010
Capability studies completed per GS-0007 with capability Cpk > 1.33
Identified as “Key” on control plan (symbol or words)
Statistically valid control method which will maintain Cpk>1.33
K
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Production control method
K
Acceptable for key characteristics
Sampling to Print Limits
Checking Every nth Piece or sample from a lot to Print Limits
Not OK
Sampling to Reduced Limits
Checking every nth piece or samples from a lot to Less than Print Limits
Restudy
May be OK
Capability Study Completed every XX Months
If Short Term (30pc) Capability
Setup Check
Defined number of parts checked at Set-up
Is High (Cp>2.5) and tool life
Tool Control
Characteristics are known/reliable
First and Last Parts checked from Tool
And maintains Cpk > 1.33
Tool Changes at Defined Life (# Parts or # Minutes)
Modified SPC
Sampling to Process Limits, Samples Fall within +/- 3 Sigma Limits
Short Run SPC
Short Run Statistical Process Control
Ok if Maintains
SPC Control Charts
Cpk > 1.33
Statistical Process Control (Xbar and R)
Pre-Control
Target Area Control; 5 Pcs at Set-up 2 Samples to
50% Spec Limits
Danfoss Power Solutions
OK for Any Capability
As long as 5 & 2 rule followed
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Process control
Requirements
 Safety and Key Characteristic
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Identified as Safety on PFMEA & Assigned Severity = 10
Identified as Safety on Control Plan with an Error Proof (Poke-Yoke)
documented on Control Plan
Production Control with Variable Gauging & GR&R<20% completed per GS-0010
(in addition to error proof)
Capability Studies Completed per GS-0007 with capability Cpk > 1.33
Statistically Valid Control Method which will maintain Cpk>1.33
(in addition to error proof)
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Process control requirements

Process characteristic PPAP requirements


Identified as “Process” on PFMEA & Assigned severity = 4
Identified as “Process” on Control plan
X
P
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Agenda

GS-0004









Purpose
Scope & Application
Definitions
Responsibility
Determining Special Characteristics
Documentation
PPAP and Process Control Requirements
Drawings created before GS-0004E
Summary/Q&A
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Comparing revision E to
Previous revisions of GS-0004


Drawings created before GS-0004 Rev E used 2 symbols
(Critical and Key) for performance characteristics
GS-0004 Rev E to the standard reduces this to 1
C
or
K
Legacy drawings created
before GS0004 rev E
Danfoss Power Solutions
=
K
Interpreted As
GS0004 rev E & after
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Comparing revision E to
Previous revisions of GS-0004
Also Remember: “border” cases from the “S x O” method (i.e.
Occurrences of 4,5 & 6 and Severities of 5 & 6) to determine if
classification as a “Key” characteristic is really warranted.
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Agenda

What GS-0004 covers









Purpose
Scope & application
Definitions
Responsibility
Determining special characteristics
Documentation
PPAP and process control requirements
Drawings created before GS-0004E
Summary/Q&A
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Special characteristics summary




Special characteristics are identified by product engineering and process
engineering during development and formally documented on
engineering drawings, specifications, and control plans
The design FMEA is the basis for determining special characteristics
There are 3 kinds of special characteristics

Safety
characteristics affecting safety

Key
characteristics affecting satisfaction

Process
characteristics affecting manufacturing Processes
The purpose of special characteristics is to focus attention on the
“Vital Few” characteristics most important for product function &
customer satisfaction
Danfoss Power Solutions
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Special characteristics summary

Special Characteristics have required levels of process performance and
process control that must be validated and documented as part of the
PPAP process
Gauging
Capability
Process Control
Attribute or
Variable
No Special
Cause Defects
Error Proof
Key
Variable
GRR<20%
Cpk>1.33
Statistical Control to
Ensure Cpk
Maintained
S+K
Variable
GRR<20%
No Defects &
Cpk > 1.33
Error Proof +
Statistical Control
Not Defined
Cpk>1.0
Not Defined
Safety
Process
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Frequently asked questions list














Why did we change the old Standard?
How did we change the old Standard?
Why did we create a Safety Characteristic?
Why are S’s allowed?
Where do we find the Ss and Ks for Assembly and Testing?
Do we put S’s or K’s on the product outline drawing?
How do we communicate S’s or K’s to customers ?
Should ‘K’ be used for Cleanliness?
What is the Best Process flow to Follow when Determining K’s and S’s?
GS0004 States that the following Severities should be used for PFMEA’s
When and to what products do we start to apply the new GS-0004?
Do we need to upgrade the old prints/ drawings?
How are we going to provide communication /training to suppliers and internal SD
operations?
Is it possible that when updating old drawings through the new process an old “C”
could turn into “S”?
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Frequently asked questions list














Do we have to have a DFMEA to assign Special characteristics?
How will this revision lead to fewer Special Characteristics?
How Does the Loss Function Help Find the Critical Few?
Do we apply Loss Function to “S”?
Can we downgrade “S” to “K” by Loss function method?
How Do we Quantify “Small” vs. “Large” Margin?
How do Design Margin and Safety Margin Relate to each other?
Why did the standard change from C & K to only K?
What to do with Drawings where the old type of critical marking (bubbles) in case
aim for a supplier change?
Why did we create a Process Characteristic?
When in the process will Process Characteristics be defined?
Can Process Characteristics be defined by process engineering and
not be documented in the drawing?
Could we have “K”, which can not be measured by Variable Gages? Actions?
Should the “S” and “K” be checked in the receiving inspection?
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Frequently asked questions list







How Do I interpret Table 4?
What is Pre-Control?
Will this apply to “Pure-Play” businesses?
Do we need to add K’s and S’s to Operator Instructions?
How should we update Product Family Drawings?
How do we handle customer requests for Keys (or Criticals)?
Where do We Document application of Loss Function for “Border Cases”?
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Q1: Why did we change the standard?
A:
Many necessary barriers/improvements were identified
 Viewed as Propel Standard



Understanding and Buy in of other divisions


If followed exactly, SON created too many critical/Key Characteristics
If a new engineer designs something and can’t make the calculations are
we are supposed put critical characteristics on the drawing???
Confusion about SON
Too Many characteristics strictly following SON



People wanted the ability to use more judgment
No good way to define Safety Criticals and drive the correct type of
control plan
Request for Process Criticals for automated assembly purposes not
Product Function
Return to FAQ List
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Q2: Who changed the Standard?
A: 
Global Team




Global Team working over a year with 2 in person meetings
Understanding Why and then how
Engineering, Quality, Purchasing





Doug McCoy
Claus Tjoernly Rasmussen
Knud Lange
Martin Raadkjaer Joergensen
Jeff Baldus

Global Engineering
Approving Group/Process Owners
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Q3: Why did we create a safety characteristic?
A: Our products and their function can impact customer’s safe vehicle
operation, if abnormal variation (special cause) happens.
The international legislation (new the Functional Safety Directive
EU/2006/45) requires evaluation and notification of safety relevant
product miss-function.
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Q4: Why are S’s allowed?
Should engineering try to eliminate them with design?
A: Yes, Absolutely but it may not be possible in all cases
As part of the approval process for S’s
We do recommend an escalation Process for the “S” approval
through Director of Engineering in each BA before adding an “S” to the
drawing
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Q5: Where do we find the Ss and Ks for
Assembly and testing?
A: The Assembly Ss and Ks will be in the AS (Assembly spec)
and the Testing Ss and Ks will be in the TS (Test spec)
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Q5: Do we put S’s or K’s on the product outline
drawing?
A: No – They should be noted Product Specification and in technical
literature not on outline drawings
Exception: Customer Specified Critical Characteristics could be shown on
customer specific outline drawings
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Q6: How do we communicate S’s & K’s to
customers ?
A: Safety Characteristics are communicated through technical literature. Key
Characteristics are communicated through the APQP/PPAP process
Return to FAQ List
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Q7: Should ‘K’ be used for cleanliness?
A: Cleanliness follows a continuous loss function but this is already
accounted for in GS-0086
Cleanliness should not be a key characteristic
Return to FAQ List
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Q8:What is the best process flow to follow
when determining Special Characteristics?

A
1.
2.
3.
4.
5.
6.
7.
DFMEA
SxO
Loss Function to review border cases
DFM and PFMEA (understand process variation and define “Ps” as necessary)
Approval for any S’s
Document on Drawing/Specification
Define which “S” and “K” go to technical literature (in EC/PPAP Teams w/ TST
representative.
Return to FAQ List
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Q9: GS0004 Defines the Severities to be used in
PFMEAs. Shouldn’t they Come from the DFMEA?
A: GS0004 States that the following Severities should be used for PFMEA’s
Safety:
Key:
Process:
Standard:
Severity=10
Severity=8
Severity=4
Severity=4
Severity for the Process FMEA does need to come from the DFMEA.
We do not, however, supply DFMEAs to our Suppliers.
By assigning Severity based on the Classification of Characteristics we can
do a very good job of transferring the Severity indirectly without providing
the DFMEA.
It also provides for a very easy way for the PFMEA to be checked when reviewing
the PPAP
Return to FAQ List
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Q10: When and to what products do we start to
apply the new GS-0004?
A: April 1, 2010 is the starting point
We apply this standard to

all new designs (Parts, Components and Final Products)

to every EC (Engineering Change)
Return to FAQ List
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Q11: Do we need to upgrade the old prints/
drawings?
A:
Not as a individual activity of updating all drawings, but if a
drawing is going to be EC’d for other reasons then the process
(slide 147) will be started also for all legacy products
Return to FAQ List
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Q12: How are we going to provide communication/training to
suppliers and internal Danfoss Power Solutions operations?
A: Procurement is responsible for training external suppliers to this
standard. Quality is responsible for training internal suppliers to this
standard
Return to FAQ List
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Q13: Is it possible that when updating old drawings through the
new process an old “C” could turn into “S”?
A: Yes, this is possible, when we create / review DFMEA we could
identify Severity >9. “S”s created in this way still require
approval
C
?
S
Return to FAQ List
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Q14: For old drawings we do not even have a DFMEA, do we
need to create one, or can we jump directly to the Quality
Loss Function?
A: It is greatly preferred/recommended to have a DFMEA.
However, if a DFMEA can not be created the Loss Function Methodology
can be used
Return to FAQ List
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Q15: How does this compare to previous
standards
Also Remember: “border” cases from the “S x O” method (i.e.
Occurrences of 4,5 & 6 and Severities of 5 & 6) to determine if
classification as a “Key” characteristic is really warranted.
Return to FAQ List
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Q16: How can loss functions help find the critical few
A: Helps to assess border cases from the SxO
Quality Loss Method
S x O Method
Return to FAQ List
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Q17: Do we apply loss function to “S”?
A: No, we apply loss function only for “K”
(normal variation and common cause) border cases
Return to FAQ List
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Q18: Can we downgrade “S” to “K” by loss
function method?
A: No, but through redesign (robust design) we can change the severity
rating down to < 9
Return to FAQ List
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Q19: How do we quantify “small” vs. “large” margin?
A:
Refer to the GS-0002 DFMEA Occurrence table
No Margin
Small Margin
82 High Margin
Return to FAQ List
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Q20: How do design margin and safety
margin relate to each other?
A:
Lower
Specification
Limit
Upper
Specification
Limit
Safety Margin
Design
Specification
Design Margin
Normally Expected
Process Variation
Abnormal
Process Variation
Note: Normally Expected Variation is for a process with 100% Sort and a GRR of 50%
Return to FAQ List
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Q21: Why did we change from C & K to only K
A: We wanted to reduce the complexity. Reduce the amount of time
discussion/ negotiating C or K and reduced process control
requirements means reduced costs
C
or
K
Legacy Drawings Created
Before GS0004 Rev E
K
=
Interpreted As
GS0004 Rev E & After
Return to FAQ List
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Q22: What to do with drawings where the old type of critical
marking (bubbles) if we change suppliers?
A: The Drawing needs update to the new GS. For the first RFQ the old
drawing can be used, but for each next step (pre-order) an updated
drawing must be used
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Q23: Why did we create a Process Characteristic
A: Primarly to accommodate automated assembly
For automated assembly you often have a robot grabbing the part on a nonfunctional area and then assembling into a tight clearance
Robot Grabs d2 and installs
spool into bore
If Concentricity (
) of d2 to D1 is not important
for function but is necessary for
Automated assembly. Concentricity of d2 to D1
would be a Process Characteristic.
Return to FAQ List
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Q24: When in the process will Process
Characteristics be defined?
A: See FAQ 8: In Step 4 after the loss function step
Return to FAQ List
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| 87
Q25: Can Process Characteristics be defined by process
engineering and not be documented in the drawing?
A: Yes, “P” can be in the Control Plan for so called “technological dimensions” or
“in-process dimensions”. These are characteristics, which must be “under
control” already before the print dimension has been manufactured.


e.g. bearing diameter on the shaft before heat treatment and
finishing
“P” on the print /drawing is always a final dimension and is not a
“in process” dimension
Return to FAQ List
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Q26: What If we have a “K” which can not be measured by
Variable Gages?
A: Because we want to keep “K” features “on target with minimum variation”
we want to have variable gauges to control them. Attribute gauges only
keep features “in print”
1) First use the loss function method to make sure it should be a Key
characteristic
2) During the DFM session see if there are other ways to measure or
control

measure the tool not the hole


use other feature that can be measured easily and directly correlate to the key
characteristic
Discuss it as a team; be creative
3) Attribute gages can be used if the tolerances are reduced from the
specification.
if an attribute gage is the only available process control for a key feature
you might consider options like pre-control with “Green” and “Yellow”
attribute gages.
Return to FAQ List
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Q27: Should the “S” and “K” be checked in the
receiving inspection?
A: Yes. We focus on “S” and “K” features during DFM and the PPAP process.
During DFM we discuss
For all “S” and “K” features the loss function, Capabilities, Gauging, and control plans
During PPAP we approve
 The suppliers ISIR (all dimensions checked to our print)
 The Suppliers Control plan (all “P”,”K” and “S” shown)
 The suppliers Gage R&R and Capability Studies (“K”)
Any new parts should come through Receiving Inspection for the first 3 shipments where
“S” and “K” checks would be part of the inspection. If there are no problems the parts can
either stay in Receiving Inspection (every shipment or skip lot) or be removed.
Should we see (or suspect) that the supplier is not “in control” we should check “S” and “K”
in the receiving inspection as a containment, and also in parallel to work with the supplier
to improve the process capability and control.
Return to FAQ List
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Q28: How do I interpret table 4?
Pre-control at 50% “Green Zone” and “Print Limits” are
referencing the tolerance on the (Design) Engineering
Drawing?
If The Engineering Print Tolernace is + 0.1
Print Limits = + 0.1
50% Green Zone is + 0.05
A: “check 1/10 to print limits” means to check every
10th part made to make sure it is “in print”. Note this is
not a suitable for Key characteristices
Return to FAQ List
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Q29: What is Pre-control?
A: “Pre-Control” is a statistically based control method.
It is also sometimes referred to as “Target Area Control”
The embedded materials provide more information.
Return to FAQ List
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Q30: Will this apply to “Stand-Along” businesses
(Turolla, Comatrol,…)?

A: Non-core business will be able to define there own quality systems
Return to FAQ List
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Q:31 Do we need to add K’s and S’s to operator
instructions


Q:Do they need to be on the operators instructions at the assembly line.
Should it be called out in Standard Work?
A:They are required to be called out on the control plan which is different than
the operator method instructions
(standard work, Computer screens at workstations, etc.) You may wish to
identify K’s and S’s in these documents but it is not required
Return to FAQ List
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Q32: Updating product family drawings

If we are developing new frame sizes in a Family using the new Special
Characteristics Standard should we go back and change the drawings on
the previous frame sizes?

Yes it is recommended; many of these parts will be going through the same
manufacturing cells (both internally and externally) this allows us to have
common production controls for the family
Return to FAQ List
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Q33: How do we handle customer requests for
Keys (or criticals)
A: Important first is to understand that we are on the same page. What does the
customer really want:
-To be in print for every unit?
-Have statistical data about the feature? (especially valve settings is a good
example)
-achieve a certain cpk?
To obtain a common understanding a long discussion w/ some training elements
(GS0004 and GS for PPAP) to be used may be needed. This discussion should involve
Product Engineering (in addition to Operations and Quality)
As a result we may have to agree to put a "Key" in, but also change our tolerances at
the same time, so we have no need to change the manufacturing process. Change of
tolerance can be calculated from cpk=1 to cpk=1.33 easily
Changes to tolerance can affect Test Cycle time and First Pass Yield so it is important
to include Operations in the discussion.
Return to FAQ List
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Q34: Where do we document application of loss
function for “Border Cases”

A: Best location is inside the D-FMEA where the RPN number is. You can
put a comment into the field how the loss function is looking and the
conclusion to leave or take away the key.
Return to FAQ List
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Break
15 min
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Advanced
Special Characteristics
Materials
For those needing to know more
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Advanced topics agenda



Loss function concept
Minimizing losses for a population
Examples
Danfoss Power Solutions
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| 100
How Satisfied would YOU be if the temperature in this room
was 22.8C? What would be your loss?
Upper
Temperature
Limit
5% Loss
Of Productivity
No Loss
Of Productivity
Completely Dissatisfied?
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Temperature
Limit
*
Somewhat Dissatisfied?
*
Completely Satisfied?
21 ºC
69.8 ºF
Danfoss Power Solutions
22 ºC
71.6 ºF
TR-0024 Special Characteristics Training for GS-0004
*
23 ºC
73.4 ºF
| 101
What would your satisfaction be over the entire
temperature range?
5% Loss
Of Productivity
No Loss
Of Productivity
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
*
*
*
*
*
21 ºC
69.8 ºF
Danfoss Power Solutions
Upper
Specification
Limit
**
*
*
*
22 ºC
71.6 ºF
TR-0024 Special Characteristics Training for GS-0004
*
23 ºC
73.4 ºF
| 102
Are you sure it is not like this?
5% Loss
Of Productivity
No Loss
Of Productivity
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Temperature
Limit
*
*
Why
Not?
* * * * * * * * **
21 ºC
69.8 ºF
Danfoss Power Solutions
Upper
Temperature
Limit
22 ºC
71.6 ºF
TR-0024 Special Characteristics Training for GS-0004
23 ºC
73.4 ºF
| 103
Quality loss function (Taguchi)
Loss
Traditional:
product within
specification is all
equally “OK”
Taguchi
Target
Traditional
Taguchi: When a
characteristic moves
away from a target value
increasing loss occurs
Specification Limits
Danfoss Power Solutions
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Is the quality loss function real?
Loss
Taguchi
Traditional:
product within
specification is all
equally “OK”
Target
Traditional
Taguchi: When a
characteristic moves
away from a target value
increasing loss occurs
Specification Limits
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Quality Loss Function - example
Taste of your favorite beer?
(Customer Dissatisfaction)
Quality Loss
Lower
Specification
Limit
*
*
*
*
*
Too
sweet
Danfoss Power Solutions
Upper
Specification
Limit
**
*
*
*
Normal
TR-0024 Special Characteristics Training for GS-0004
*
Too
bitter
| 106
Danfoss Power Solutions
(Customer Dissatisfaction)
Quality Loss
What about other Loss Functions?
Continuous/minimum is best
On target with
minimum variation
produces lowest
amount of loss
*
*
*
* * * *
TR-0024 Special Characteristics Training for GS-0004
*
| 107
What about other loss functions?
Danfoss Power Solutions
(Customer Dissatisfaction)
Quality Loss
Continuous/Maximum is best
On Target With
Minimum Variation
Produces Lowest
Amount of Loss
*
*
*
* *
* * *
TR-0024 Special Characteristics Training for GS-0004
| 108
Quality Loss Function - example
How satisfied are you with the cleanliness of a plate in a
restaurant?
(Customer Dissatisfaction)
Quality Loss
No
Dirt
*
Which
One?
*
*
* * * *
Clean
Danfoss Power Solutions
Upper
Dirt
Limit
Normal
TR-0024 Special Characteristics Training for GS-0004
*
Very
Dirty
| 109
Quality Loss Function - example
How satisfied are you when paying for 20 liters of fuel
and getting something different?
Which
One?
(Customer Dissatisfaction)
Quality Loss
*
*
*
*
19.75
Danfoss Power Solutions
* * * *
20.00
Liters actually delivered
TR-0024 Special Characteristics Training for GS-0004
20.25
| 110
What would Loss Functions like these mean?
Quality Loss
When this characteristic is
Just outside of specification there
is a total quality loss
(High customer dis-satisfaction)
LSL
Nom
USL
Quality Loss
When this characteristic is
far outside of specification
There is a small quality loss
(Some customer dis-satisfaction)
LSL
Danfoss Power Solutions
Nom
USL
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| 111
Quality Loss
LSL
USL
No Loss in Specification
LSL
Danfoss Power Solutions
Nom
Quality Loss
No Change in Quality Loss
What would these Loss Functions mean?
Nom
TR-0024 Special Characteristics Training for GS-0004
USL
| 112
Quality Loss
What would these Loss Functions mean?
LSL
Nom
USL
Quality Loss
Loss when Out of Specification – Low Margin
LSL
Nom
USL
Loss when Out of Specification – High Margin
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| 113
Classifying Loss
Functions
114
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| 114
Definition:
Loss inside specification or outside of specification
 Loss Inside of Specification (IN)
 Loss outside of specification (Out)
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Definition: design margin
Design Margin
The Difference Between The Specification Limit
And Where Noticeable Customer Dissatisfaction (loss) Begins
Large Margin
Small Margin
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Definition: Loss slope
 Shallow


Loss is small near starting point
Must vary a lot to be noticed
by most
 Steep


Loss happens suddenly
Noticeable immediately
by Most/All
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Classifying Loss Functions
Loss Function
Specification
Margin
Slope
Danfoss Power Solutions
IN
None
Steep
OUT
Small
Shallow
Steep
Shallow
TR-0024 Special Characteristics Training for GS-0004
Large
Steep
Shallow
| 118
Using Loss Functions to identify key
characteristics
Loss Function
Specification
Margin
None
IN
OUT
Small
Slope SteepShallowSteep
Key
Characteristic
Danfoss Power Solutions
Shallow
May Be Key
Characteristics
TR-0024 Special Characteristics Training for GS-0004
Large
Steep
Shallow
Standard
Characteristics
| 119
Comparing SxO method to quality loss method
SxO
Table
Quality Loss
Continuous
Low Margin
High Margin
Danfoss Power Solutions
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| 120
Comparing SxO method to quality
loss method
Danfoss Power Solutions
TR-0024 Special Characteristics Training for GS-0004
SxO
Table
Loss
Slope
| 121
Comparing S x O method to quality
loss method
Quality Loss Method
Danfoss Power Solutions
S x O Method
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| 122
Advanced topics agenda



Loss Function concept
Minimizing losses for a population
Examples
Danfoss Power Solutions
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| 123
Losses for a complete population
Normally
Expected
Variation



 
 
  
Danfoss Power Solutions
Upper
Specification
Limit
















Loss
Function
Total Customer Loss
Lower
Specification
Limit


 
 
  
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| 124
The general case


Total Loss =
Danfoss Power Solutions



P( y) * L( y)dy
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Knowing the “Normally expected variation” &
the loss function predicts the total loss

Normally expected variation
 Variation which should be expected produced by the process
operating under control

Capabilities

Measurement Variation (GRR)

Control plan adjustments

Tool wear

Set-ups

Etc
Danfoss Power Solutions
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Predicting normally expected (Long Term)
variation
Long Term Variation
=
f(
Variation which should be
expected produced by the
process operating under
control.
Capabilities
Measurement Variation
(GRR)
Control plan adjustments
Tool wear
Set-ups
etc
Danfoss Power Solutions
,
,
)
How Well
We See
How
Repeatable
Short Term
How We
Control &
Adjust
Gauge
R&R
(GS 0010)
Capability
Study
(GS 0007)
Control
Plan
(GS 0012)
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Creating the model
- The Effect of short term (30pc) capability

Short Term Capability Study


Is this the
Normally Expected
Variation? Why Not?
Cp = 2
Cpk = 2
Min
Nom
Max
What About
Gage R&R?
Danfoss Power Solutions
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Creating the model
- The effect of GRR
“Spread” We
See
Observed
Variation
“Spread” Of
“Spread” Of
Process
Measurement
Actual
Variation
Danfoss Power Solutions
TR-0024 Special Characteristics Training for GS-0004
Measurement
Variation
| 129
Creating the model
-
Effect of GRR

Short Term Capability Study

Cp = 2/Cpk = 2
Cp/Cpk = 1.46
• Gage R&R
- GRR = 40%
Is this the
Normally Expected
Variation? Why Not?
Mean Shifts
Min
Nom
Max
What About
Mean Shifts
Over Time?
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Creating the model
-
Effect of control plan on mean shifts
 Short Term Capability  Cp = 2/Cpk = 2
 Measurement Variation  GRR = 40%
 Mean Shift (Control Plan)  Samples To Print
Mean
Min
Danfoss Power Solutions
Nom
Max
TR-0024 Special Characteristics Training for GS-0004
This is the Normally
Expected Variation!!
| 131
Simulation modeling
Model Assumptions
Allowable mean shift determined by Control Plan
 Check 1/n to print limits Allowable Mean Shift is Specification
Pre-Control/Target Zone Control Allowable Mean Shift is Target Zone
SPC  Allowable mean shift is control limits on Xbar Chart
3s Value determined by Combination of Short Term Capability and GRR
 S = sqrt(s^2process + s^2measure)
 alternatively if SPC is used the limits on the Range Chart can be used


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Examples



Cp =.8
Control = 100% Inspect
100% GRR
Trapezoidal Distribution
Gage R&R
LSL
USL
LSL
USL
Over Time
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Examples




GRR = 5%
Cp = 10
Control: Check 1/10 to Print
Set up @ USL/Run to LSL
Square Distribution
Gage R&R
USL
LSL
LSL
USL
Time
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Examples



GRR = 25%
Cp= 1.83
SPC with +/- 1.5 Mean Shift
LSL
Trapezoidal Distribution
USL
Gage R&R
LSL
USL
Time
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Long term distribution simulator

Lets Look at a typical scenario for standard
features



Control Plan = Samples to print
Capability = 1
GRR = 30%
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Simulation results
Lower
Spec
Limit
0.0160
0.0165
0.0170
0.0175
Upper
Spec
Limit
0.0180
0.0185
0.0190
0.0195
 Simulation Predicts Parts Can be Made Outside of Specification Limits
(Note: Samples will not be shipped Outside of Specification Limits)
Danfoss Power Solutions
TR-0024 Special Characteristics Training for GS-0004
0.0200
| 137
What distribution would have lowest total quality loss?
How can we know?
5% Loss
Of Productivity
No Loss
Of Productivity
21 C
Danfoss Power Solutions
Upper
Specification
Limit
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
22 C
TR-0024 Special Characteristics Training for GS-0004
23 C
| 138
What would be the total loss if the temperature
distribution was as shown
Total
Total Loss
Loss
5% Loss
Of Productivity
No Loss
Of Productivity
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
For these simple examples use the loss
at the middle of the bar to calculate
3.5
25%
25%
25%
25%
0.5
21
Danfoss Power Solutions
Upper
Specification
Limit
.25*3.5
.25*3.5
+.25*0.5
+.25*0.5
+.25*0.5
+.25*0.5
+.25*3.5
Total
Loss = 2.0
+.25*3.5
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 139
What would be the total loss if the temperature
distribution was as shown
5% Loss
Of Productivity
No Loss
Of Productivity
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
Upper
Specification
Limit
.10*3.5
+.40*0.5
.10*3.5
+.40*0.5
+.40*0.5
+.10*3.5
Total
Loss = 1.1
+.40*0.5
+.10*3.5
3.5
40%
40%
10%
0.5
21
Danfoss Power Solutions
Total Loss
Total
Loss
10%
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 140
What would be the total loss if the temperature
distribution was as shown
5% Loss
Of Productivity
No Loss
Of Productivity
Danfoss Power Solutions
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
Total Loss
Total
Loss
.50*0.5
.50*0.5
+.50*0.5
+.50*0.5
Total
Loss = 0.5
50%
Upper
Specification
Limit
50%
0.5
21
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 141
5% Loss
Of Productivity
No Loss
Of Productivity
Danfoss Power Solutions
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
What would be the total loss if the temperature
distribution was as shown
100%
Lower
Specification
Limit
Upper
Specification
Limit
Total Loss
1.0*0.0
Total Loss = 0
21
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 142
What would be the total loss if the temperature
distribution was as shown
5% Loss
Of Productivity
No Loss
Of Productivity
Total Loss
1.0*3.5
Total Loss = 3.5
21
Danfoss Power Solutions
Upper
Specification
Limit
100%
(Customer Dissatisfaction)
10% Loss
Of Productivity
Quality Loss
Lower
Specification
Limit
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 143
Quality loss vs. distribution
“In specification” loss functions
2.0
1.1
0.5
0.0
On Target With Minimum
Variation Produces Lowest
Total Loss for
“In Specification” Loss Functions
3.5
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Dealing with special characteristics

Continuous Loss Function


Design
 Data Based Design For Manufacturability (DFM)
Manufacturing process control
 Maintain Process on Target with Minimum Variation
 Improve Processes to meet Long Term Capability or Reduce Tolerance
Zone to XX%
 Use Variable Production Gauging
 Have Acceptable Gage R&R


Measurement Variation as % of Process Variation is more important than as a
% of specification
Run SPC or TAC control Plan

Danfoss Power Solutions
Maintain Process On Target with Minimum Variation
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| 145
Quality Loss
LSL
USL
Would being on target with minimum
variation
improve your satisfaction?
LSL
Danfoss Power Solutions
Nom
Quality Loss
No Change in Quality Loss
What would these Loss Functions mean?
Nom
TR-0024 Special Characteristics Training for GS-0004
USL
| 146
What would be the total loss if the temperature
distribution was as shown
Total
Loss
Total Loss
5% Loss
0% Loss
(Customer Dissatisfaction)
10% Loss
Quality Loss
Lower
Specification
Limit
Danfoss Power Solutions
.25*0
.25*0
+.25*0
+.25*0
+.25*0
+.25*0
+.25*0
Total
Loss = 0
+.25*0
25%
21
Upper
Specification
Limit
25%
21.5
25%
22
TR-0024 Special Characteristics Training for GS-0004
25%
22.5
23
| 147
What would be the total loss if the temperature
distribution was as shown
100%
5% Loss
No Loss
(Customer Dissatisfaction)
10% Loss
Quality Loss
Lower
Specification
Limit
Total Loss
1.0*0.0
Total Loss = 0
21
Danfoss Power Solutions
Upper
Specification
Limit
21.5
22
TR-0024 Special Characteristics Training for GS-0004
22.5
23
| 148
What would be the total loss if the temperature
distribution was as shown
5% Loss
Quality Loss
10% Loss
(Customer Dissatisfaction)
Lower
Specification
Limit
100%
Upper
Specification
Limit
Total Loss
1.0*100%
Total Loss = 100
No Loss
Danfoss Power Solutions
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| 149
Quality Loss vs. distribution
low margin Loss Functions
0
0
100
Danfoss Power Solutions
All Distributions
“In Specification”
Produce Zero Losses
Out of Specification
Produces High Losses
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| 150
Dealing with special characteristics
Low Margin Loss Function

Design
 Design as “Flat” as Possible (Lower DFMEA Severity)
 Data Based Design For Manufacturability (DFM)

Manufacturing Process Control
 Variable or attribute gauging
 100% Sort/P-Y is OK/Attribute Gage
 Gage R&R
 Measurement Variation as % of Specification
 Attribute Gage is OK
 Guard Banding for very low margins

Low Margin Loss Function
Capability
 Determines gauging Frequency
 Important for yield

Control Plan
 100% Sort to Spec Limits is OK (with GRR considerations)
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| 151
What Would Be the Total Loss if the Temperature
Total Loss
Loss
Distribution wasLower
as ShownTotal
Upper
5% Loss
0% Loss
Quality Loss
10% Loss
(Customer Dissatisfaction)
Specification
Limit
25%
.25*0
.25*0
+.25*0
+.25*0
+.25*0
+.25*0
+.25*0
+.25*0
Total Loss = 0
25%
25%
Specification
Limit
25%
152
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| 152
What Would Be the Total Loss if the Temperature
Distribution was
as Shown
Lower
Upper
100%
5% Loss
No Loss
Quality Loss
10% Loss
(Customer Dissatisfaction)
Specification
Limit
Specification
Limit
Total Loss
1.0*0.0
Total Loss = 0
153
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| 153
What Would Be the Total Loss if the Temperature
Distribution was
as Shown
Lower
Upper
5% Loss
No Loss
Quality Loss
10% Loss
(Customer Dissatisfaction)
Specification
Limit
Specification
Limit
100%
Total Loss
1.0*0
Total Loss = 0%
154
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| 154
What Would Be the Total Loss if the Temperature
Distribution was
as Shown
Lower
Upper
5% Loss
No Loss
Quality Loss
10% Loss
(Customer Dissatisfaction)
Specification
Limit
Specification
Limit
100%
Large Special Cause(s)
is needed to produce
Customer Losses
155
Danfoss Power Solutions
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| 155
Quality Loss vs. distribution
high margin loss functions
0
All Distributions
“In Specification”
Produce Zero Losses
0
0
Danfoss Power Solutions
Out of Specification
“Common Cause” Variation
Produces No Losses
TR-0024 Special Characteristics Training for GS-0004
| 156
Dealing with special characteristics
High Margin Loss Function
High Margin Loss Functions


Design – Good Job!
Manufacturing Process Control
 Gage R&R


No formal studies needed. Any good measurement system needs to have variation
less than 30% of Specification
Capability



No Formal Study needed
Cpk >1
Control Plan
 Process control which ensures there are no Special Causes which
cause an abnormal process shift large enough so that a loss will
occur



Danfoss Power Solutions
First/Last Piece Checks
Set up verification + Tool Life/Broken tool reaction
etc
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| 157
Production control summary

“In specification” Loss Function

Minimum loss if “On target with minimum variation”


Capability Improvement for better customer satisfaction


100% Sort is not acceptable long term; containment only
“Small Margin” Loss Function





Capability, GRR, Control Plan define expected variation
No loss as long as “in Specification”
100% sorting OK if capability bad
Capability improvements for scrap reduction
GRR important if sorting
Large Margin Loss Functions

No loss unless there is “unexpected variation” due to process going out of
control

Focus on controlling assignable causes through PFMEA and Error-Proof

Consider increasing tolerance for scrap reduction

Simple controls (1st Piece/last piece, broken tool detection, etc)
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Advanced topics agenda



Loss Function Concept
Minimizing Losses for a Population
Examples
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| 159
Special characteristics using Loss Function
Example 1: 25.00 +/- .02 is spool diameter
1)
Determine the customer loss(es)

As Diameter (D1) gets bigger
 Leakage decreases
 probability of stiction increases

As Diameter gets smaller
 Leakage increases
 probability of stiction decreases
2)
Determine where losses begin
 Leakage changes with diameter (clearance) throughout tolerance
 Stiction/hysterisis change throughout tolerance
3)
Select type of Loss Function


Continuous Loss Function
Steep slope
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Special characteristics using FMEA method
Example 1: 25.00 +/- .02 is Spool diameter
DFMEA SEVERITY
DFMEA OCCURRENCE

Severity

Occurrence
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Using Loss Functions to identify key characteristics
LOSS FUNCTION
IN
Specification
Margin
None
OUT
Small
Steep Shallow Steep
Slope
Key
Characteristic
Danfoss Power Solutions
May Be Key
Characteristics
Large
Shallow
Steep
Shallow
Standard
Characteristics
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| 162
Is it a special characteristic?
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Example Loss Function
Example 2: 25.00 +/- .02 is clearance hole

Determine the Customer Loss(es)


As Hole Gets Smaller
 Pin Won’t Go Through Hole
 Product Won’t Function
As Hole Gets Larger
 Stress in part increases
 2)


 3)


Determine where losses begin
Pin Might Not Go Through Hole at 24.98
Stress is not a concern until Hole is 28.5
Select Type of Loss Function
Low Margin Loss Function
Steep Slope
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Using loss functions to identify key characteristics
LOSS FUNCTION
IN
Specification
Margin
Slope
Key
Characteristic
Danfoss Power Solutions
Small
None
Steep
OUT
Shallow
Steep
Shallow
May Be Key
Characteristics
TR-0024 Special Characteristics Training for GS-0004
Large
Steep
Shallow
Standard
Characteristics
| 165
Example FMEA
Example 2: 25.00 +/- .02 is Clearance hole
DFMEA SEVERITY
DFMEA OCCURRENCE

Severity

Occurrence
Danfoss Power Solutions
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Is it a special characteristic???
Danfoss Power Solutions
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| 167
Using Loss Functions to identify key characteristics
Redesign
Opportunities
LOSS FUNCTION
Specification
IN
None
Margin
Slope
Steep
Key
Characteristic
Danfoss Power Solutions
OUT
Large
Small
Shallow
Steep
May Be Key
Characteristics
Shallow
Steep
Shallow
Standard
Characteristics
TR-0024 Special Characteristics Training for GS-0004
| 168
Redesign?
Example 2: 25.00 +/- .02 is clearance hole
Fit
Maybe?
Stress
Redesign!
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After Redesign
Example 2: 25.00 +/- .02 is Clearance hole
DFMEA SEVERITY
DFMEA OCCURRENCE

Severity

Occurrence
Danfoss Power Solutions
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| 170
Is it a Special Characteristic???
Danfoss Power Solutions
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| 171
Example Loss Function
Example 3: 25.00 +/- .02 is Shaft Diameter

Determine the Customer Loss(es)

As Diameter Gets Bigger



As Diameter Gets Smaller

 2)


 3)


Stress Decreases
Coupling Won’t Go on Shaft
Stress increases
Determine where losses begin
Coupling Does not assemble when Diameter is 25.15
Stress is too high when Diameter is below 24.5
Select Type of Loss Function
High Margin Loss Function
Steep Slope
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Example Loss Function
Example 4: 25.00 +/- .02 is shaft diameter
 Determine the customer loss(es)
 Determine where losses begin
 Select type of Loss Function
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Example 3: 25.00 +/- .02 is Shaft Diameter
DFMEA SEVERITY
DFMEA OCCURRENCE

Severity

Occurrence
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Is it a Special Characteristic???
Danfoss Power Solutions
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| 175
Finish!
Thanks for your attention!
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Change History






Slide 51 “Production Control Method
Acceptable for Key Characteristics” :added “And maintains Cpk > 1.33”
to yellow box
Slide 63 “FAQ 5” :added “product” to outline drawing description.
Slide : removed “Propel EU Internal Training for Purchasing /SQA and
Operations will be offered by Eckhard Skirde and Marina Nissen in Q1
2010”
Added new FAQ’s
Changed “Border Areas” slides to be correct
15 Oct 2013: changed logo and coloring on slides
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| 177