Quality by Design - Alex Zenanko's Document Archive | My
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Transcript Quality by Design - Alex Zenanko's Document Archive | My
Alex Zenanko & Josh Parker
1) “Quality by Design”(QBD)
•
The solutions offered by QBD
2) “Sequential Engineering”(SE)
•
Slow, Traditional Method
3) “Concurrent Engineering”(CE)
•
Fast, Multi-tasking Modern Method
•
Implementation
4) Applications
5) ………..More to be added
I.
What is “Quality by Design”?
•
1)
“The practice of using a multidisciplinary team to conduct
conceptual thinking, product design, and production planning all
at one time.” [T.Q.M. 349]
Incorporates:
New Product Introduction(NPI)
1)
•
The Introduction of a new product to market
Sequential Engineering philosophy
2)
•
Compartmentalized engineering process where one department
fulfills their responsibilities, and then hands it off to the next
repeating this process until the desired product is achieved
Concurrent Engineering philosophy
3)
•
•
Is analogous to QBD
Parallel task are performed that would be sequential in SE
Classic Design Process
Characteristics:
Slow and Inefficient
Weak Communication
Time demands
Evolution:
Industry adapts old systems
to meet new demands
“ Stage Gate Systems”
“Product Funnels”
“Concurrent Engineering”
All of these new systems
package information to be
passed on to other teams
[above] Sequential Engineering Modified
with Data Packaging Steps at various stages
I.
What caused the transition from SE to CE?
Time became the deciding factor for success causing CE to emerge
Budget Globalization brought more competitors to the market
II.
Goals:
1.
2.
3.
4.
5.
III.
Customers + (happiness\retention\communication\etc)
Decrease time to market by overlapping different tasks
Shorten the task being performed
Decrease Cost “The bottom line”
Increase Quality
Teams = Move the product from concept to market by performing a task
1.
2.
Ex. Task = Marketing, R&D, Logistics, Test, Production, Quality
Everyone must work together towards a common goal
I.
Pros:
Faster than Sequential engineering
Cooperative, Open exchange of information
“Decreases design changes”
Decisions made with respect to different job
requirements
Promote internal communication
Customer service more connected to those with
knowledge/solutions
Cons:
I.
•
•
•
Design changes still undermine performance gains
Unforeseeable events causing a design to be cancelled will
have wasted more resources than SE
Is inefficient when a diverse group to be constantly forced to
make collective decisions. [ex: Congress]
Requires abundance of cooperation just to function normally
•
•
•
Not ‘organic’ – Processes can flourish using SE naturally.
Who is responsible for what problem when attributable to
any?
Is it possible to have all members of an organization work
towards a common goal?
What forces naturally oppose creating/enforcing a common goal?
[Individual] Education/Beliefs/Values/Attitude/Promotions/Personality
[Organizational] Competition/Time/Leadership/Capability/Cost/Gov’t
Teams
Communication
Goal Setting
Coordination
Types of Teams?
Program management
Technical
Design-Build
Product developers
Research & development
Design
Production
Test
Logistics
NASA
The Jet Propulsion
Laboratory
Project Design Center
Construction
Industry
Boeing 777 aircraft
Cummins Engine
Digital satellite system at
Thomson Consumer
Electronics
Airborne vehicle
forward-looking infrared
night vision system at
Texas Instruments
Has three building
blocks (foundation):
Product Design
Process Design
Supply Chain Design
3DCE is defined as:
The simultaneous
development of
products, processes,
and supply chains.
Product Design
Deals with the product’s specifications
Process Design
Concentrates on methods to manufacture product
Supply Chain Design
In sourcing, outsourcing, suppliers, and customers
Relationship between organization and other members
of supply chain
3-D
CAD
Rapid Prototyping
Rapid Tooling
Some benefits in large companies in 1991
Development and production lead time reductions
Product development time reduced by up to 60%
Production spans reduced to 10%
Total microelectronics fabricating process time reduced
up to 46%
Yield improvements of up to 4 times
Field failure rates reduced up to 83%
Improved quality of resulting end products
Higher reliability in the product development process
Increased customer satisfaction
Engineering changes per drawing reduced up to 15
times
Early production engineering changes reduced by
50%
Scrap and rework reduced up to 87%
Sequential
New product ideas on
hold
Pay workers to stand
around while waiting on
design changes
A last place competitor
Quality by Design
More time to:
Produce new product
ideas or improvements
Better use of payroll
Stay ahead of the
competition
Existence of Computer
networks
Quality Standards
Total Productive
maintenance
Quality functional
deployment
Information technology
Quality by Design
Sequential Engineering
Slow Traditional Method
Concurrent Engineering
Fast Multi-Tasking Modern Method
Applications
Benefits
Teams Required
Development and
Used in most all
Production
Quality Improvements
Engineering process
Improvements
production
manufacturing
industries
Techhnology