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
•
•
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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