Transcript PENDULUM DESIGN (cont.d)

QUALITY THROUGH INNOVATION:
Theory of Inventive Problem Solving
Gülser Köksal
Industrial Engineering Department
Middle East Technical University
2008
FAILURE OF NEW PRODUCTS
• 70-80% of new products do not survive
• Top companies get 39-50% of revenues
from new products, while less
successful companies get only 23%
• Leading cause of failure : Copying
competitors’ new products
THEORY OF INVENTIVE
PROBLEM SOLVING (TRIZ)
• G. Altshuller studied more than 1,500,000
world-wide patents.
• He extracted from these 39 engineering
parameters that cause conflict.
• Her also extracted from these 40 inventive
principles.
• He showed that over 90% of the problems
engineers faced had been solved
somewhere before.
LEVELS OF INVENTIVENESS
Level
Deg. of invent.
% of
Know. Source
solutions
# of solutions
to consider
1
Apparent solution
32%
Personal knowledge
10
2
Minor improvement
45%
Know. within company
100
3
Major improvement
18%
Know. within industry
1000
4
New concept
4%
Know. outside industry
100,000
5
Discovery
1%
All that is knowable
1,000,000
Innovation and TRIZ
Could you reverse the
fish by relocating four
sticks sliding them
parallel to their axes?
Could you reverse the
fish by relocating three
sticks sliding them
parallel to their axes?
39 System Parameters
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Weight of moving object
Weight of nonmoving object
Length of moving object
Length of nonmoving object
Area of moving object
Area of nonmoving object
Volume of moving object
Volume of nonmoving object
Speed
Force
Tension, pressure
Shape
Stability of object
Strength
Durability of moving object
Durability of nonmoving object
Temperature
Brightness
Energy spent by moving object
Energy spent by nonmoving object
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Power
Waste of energy
Waste of substance
Loss of information
Waste of time
Amount of substance
Reliability
Accuracy of measurement
Accuracy of manufacturing
Harmful factors acting on object
Harmful side effects
Manufacturability
Convenience of use
Repairability
Adaptability
Complexity of device
Complexity of control
Level of automation
Productivity
The Most Frequently Used Ten
Inventive Principles
35. Parameter changes (Transport oxygen or nitrogen or petroleum
gas as a liquid, instead of a gas, to reduce volume)
10. Preliminary action (Pre-pasted wall paper)
1. Segmentation (Modular furniture)
28. Mechanics substitution (electronic voting)
2. Taking out (Locate a noisy compressor outside the building where
compressed air is used
15. Dynamics (Adjustable seat)
19. Periodic action (Replace a continuous siren with a pulsed sound)
18. Mechanical vibration (Destroy gall stones or kidney stones using
ultrasonic resonance)
32. Color changes (Colormatic lenses)
13. 'The other way round' (Walking stairs)
Contradiction Matrix Solution:
Short Car
Contradiction:
Improving parameter: Length of moving object (3)
Worsening parameter: Harmful side effects (31)
Inventive principle: Another dimension (17)
Solution: Mercedes-Swatch made Smart Car
Source: Popular Science, January 1998, p.82.
Example: How to redesign a beverage can to reduce the cost?
CONFLICT:
The can wall must be thinner
to reduce cost
(eng. parameter #4: length of a
stationary object)
and thicker to improve load
bearing capacity
(eng. parameter #11: tension,
pressure).
Source: Glenn Mazur www.mazur.net/triz
Inventive principles #1 segmentation, #14
spheroidality, and #35 change physical or chemical
parameters can be applied.
SOLUTION: Corrugate the wall (segmentation),
add a curve from can wall to top (spheroidality),
and use a stronger metal alloy (chemical
parameter).
Source: Glenn Mazur www.mazur.net/triz
Evolution Patterns of Technological Systems
Trend 1 -
Technology follows a life cycle of birth, growth, maturity, decline
(airplanes)
Trend 2 -
Increasing ideality (evolution of computers)
Trend 3 -
Uneven development of subsystems resulting in contradictions.
(speed of computers vs. modem lines)
Trend 4 -
Increasing dynamism and controllability (manual gearbox to
CVT)
Trend 5 -
Increasing complexity, followed by simplicity through
integration (evolution of stereo music systems)
Trend 6 -
Matching and mismatching of parts (automatic brake system)
Trend 7 -
Transition from macrosystems to microsystems using energy
fields to achieve better performance or control (cooking systems)
Trend 8 -
Decreasing human involvement with increasing automation
(clothes washing systems)
S Curve
Sales
(System Characteristics)
Maturity
4
Growth
3
Decline
6
2
1
5
Birth
Time
1. Manual attempts to fly fail.
2. Wright Brothers fly at 30mph in
biplane.
3. Military use in WWI. Financial
resources available.
Speeds increase to
100mph.
4. Wood and rope frame aerodynamics
reach limit.
5. Metal frame monoplane developed.
6. Several new types of airplanes have
been developed but limited
use of biplanes still exists.
An Application of Trend 7 to dishwasher
technology evolution
Segmentation of substances and objects
Washing
with water
Using steam
Using sound
waves,
microwaves
An Application of Trend 7 to dishwasher
technology evolution
Surface segmentation
Current surfaces of
dishwashers and utensils
Using lotus effect surfaces in
dishwasher walls and utensils
CONCLUSION
• Since TRIZ can help engineers and developers solve
technical contradictions and invent new technologies,
it's use in New Product Development is very
important.
• Combined with Quality Function Deployment (QFD),
a company should be able to identify important
customer requirements and then solve any technical
bottlenecks that arise. TRIZ can also help identify
new functions and performance levels to achieve
truly exciting levels of quality.