Transcript No Slide Title

QUALITY BY DESIGN
Quality Function
Deployment
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
1
TOTAL QUALITY
Qualitas adalah segala keseluruhan karakteristik dari sebuah
entiti yang berdasarkan pada kemampuan barang/produk tersebut
untuk memenuhi kebutuhan baik yang tersirat maupun yang tidak.
(ISO/DIS 8402-1991 )
Bergantung pada kedalaman dari lingkup aplikasinya, ISO telah menggariskan
tiga standar dimana qualitas dapat dipenuhi, yaitu :
ISO 9001 : Quality system, Model for quality assurance in design/development,
production, installation ad servicing
ISO 9002: Quality system – model for quality assurance for production, and
installation
ISO 9003: Quality system – model of quality assurance in final inspection and
tests.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
2
TOTAL QUALITY
QUALITY ENGINEERING
OFF-LINE QUALITY CONTROL
Engineering Optimisation using statistical methods
Process Design
(Process Optimisation)
Product Design
(Product Optimisation)
System Design Innovation
Parameter Design Optimisation
Tolerance Design Optimisation
ON-LINE QUALITY CONTROL
Process control
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
3
TOTAL QUALITY
ON-LINE QUALITY CONTROL
Refers to activities that monitor quality
characteristic during or after production and
define the statistical rules for determining
whether actions should be taken to correct
changes in he underlying process
PROCESS CONTROL
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
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TOTAL QUALITY
OFF-LINE QUALITY CONTROL
Refers to activities that occur during
product and process design stage.
Quality by design means that a structured
off-line methods are used to determine the
design configuration that meet customers
need and are robust
Engineering Optimisation Using Statistical Methods
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
5
TOTAL QUALITY
OFF-LINE QUALITY CONTROL
ROBUST :
product performance characteristic are
insensitive to variation in manufacturing
and operating environments.
Robustness by design reduces the need of
the company to rely on extensive
monitoring and controls
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
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TOTAL QUALITY
OFF-LINE QUALITY CONTROL
Quality Function Deployment
A structured process for taking the
needs and desires of the customers
and translating them into technical
engineering requirements
Dr A. Riza Wahono :
Product Development
TAGUCHI Method
Incorporates variability measures
and technical requirement
generated from customers input
into the evaluation of alternative
product design
Create robust design
“ Qualitas krn Desain ”
modul 5
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SYSTEM DESIGN
INNOVATION
QUALITY FUNCTION DEPLOYMENT
Quality Function Deployment (QFD) is a systematic
approach for the design of new product or services based
on close awareness of customer desires coupled with
integration of corporate functional groups
This approach is a set of planning and communication
techniques that focus and coordinate organisational
capabilities in order to develop products that most
closely meet customer’s actual needs
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
8
QUALITY FUNCTION
DEPLOYMENT
QFD can be seen in two lights :
1. As a comprehensive organisational mechanism for
planning and control new product development
2. As localised techniques to translate the requirement
of one functional group into the supporting
requirement of a downstream functional group.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
9
QUALITY FUNCTION
DEPLOYMENT
QFD requires multifunctional team of expert to
participate simultaneously in a complex analytic
exercise, bringing diverse perspective to bear on key
issues of design
In localised usage, QFD serves both technical and
organisational function
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
10
QUALITY FUNCTION DEPLOYMENT
PRIMARY EXPECTED OUTCOMES :
1. Increased awareness of customers desires,
improved product with focus on actual customer
wants, improved product specification setting
and in general more succesful and effective product
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
11
QUALITY FUNCTION DEPLOYMENT
PRIMARY EXPECTED OUTCOMES :
2. Synergistic gain resulting from integration of
and increased effective communication between
individuals from different groups.
Such gains include understanding of each other
functional constraints and capabilities and transfer
of information earlier
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
12
QUALITY FUNCTION DEPLOYMENT
PRIMARY EXPECTED OUTCOMES :
3. Effective definition and prioritisation of new product
development activities
leading to increased understanding of trade-offs,
clear understanding of product objectives and
customer needs,
improves decision making,
a better end product
and reduced development time
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
13
QUALITY FUNCTION DEPLOYMENT
Quality Function Deployment (QFD) is a set of planning and
communication routines that focuses and coordinates skills within
an organisational first to design, then to manufacture and market
goods that customers want to purchase and will continue to
purchase “ [Hauser&Clausing]
It aims at stimulating and structuring this multidisiplinary
communication.
QFD supports a project team in identifying the needs of the
custumer and interpreting them in term of technical parameters
and target values
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
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QUALITY FUNCTION
DEPLOYMENT
PRODUCT ATTRIBUTES
PRODUCT EVALUATION
PROJECT OBJECTIVES
ENG CHARACTERISTIC
INTERACTION MATRIX
PARAMETERS INTERACTION
TECHNICAL ANALYSIS AND TARGET VALUS
FEASIBILITY
DEVELOPMENT PLAN
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
15
QUALITY FUNCTION
DEPLOYMENT
PRODUCT ATTRIBUTES
Product attributes reflecting the wishes of the customer. The attributes should
be based on the voice of the customers.
To obtain such collection of product attributes, creativity techniques can be
used as well as data obtained from through market and consumer research,
document of complaints and repairs, trend analysis and earlier QFD analyses.
In applying QFDfor the first time, it is adviseable to divide the step into 4 steps
i.e Generate, Select, Classify, and structure
The last part, the relative importance of product attributes is compared and
weighted
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
16
QUALITY FUNCTION DEPLOYMENT
CUSTOMER NEED ANALYSIS
•
•
•
Need analysis is concerned with establishing the true needs of
the customer – the ‘voice of the customer’- (VOC).
This can be obtained by extensive examination of the views and
reports of representative bodies, market data publications
(buying habits), reports giving official opinions and reactions to
products in use and also by structured interviews or customer
questionnaires.
The establishment of customer need is important. Ideally, needs
analysis should be approached by structuring interview
schedules or questionnaires around the element of the PDS.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
17
QUALITY FUNCTION DEPLOYMENT
CUSTOMER NEED ANALYSIS
•
•
The PDS primary elements should form the triggers for asking
the right questions of customers and so structured the analysis
will naturally from the basis for the PDS itself
This is to be preferred to random approaches to ascertain
customer needs, which tend to leave fundamental gaps in the
information gathered. This happens particularly if the questions
themselves are derived and driven from consideration of
existing products and customers views of those products rather
than from fundamental needs issues.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
18
QUALITY FUNCTION
DEPLOYMENT
PRODUCT EVALUATION
This step, assumes that the organisation involved has a
comparable product on the market for the specific target group.
Performance of the current product is submitted to an evaluation,
by competitive bench-marking. The earlier obtained product
attributes are used as evaluation criteria.
For each evaluation criterion it is accertained whether the
product is better, similar or worse that the competitive products
all this seen from the customer’s prespective.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
19
QUALITY FUNCTION
DEPLOYMENT
PROJECT OBJECTIVES
The evaluation provides an insight into the problems regarding
the function of the current product.
Combining these performance data with relative importance of
the product attributes is useful in assessing the opportunities for
improvement of the product and in determining the project
objectives.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
20
QUALITY FUNCTION
DEPLOYMENT
ENGINEERING CHARACTERISTIC
In this step, the new product is described in terms of engineering
characteristic.
These characteristic here called “Technical Parameters” and the
measurement of units can be based on the specifications of the
forerunners of the product or can be derived by operationalisation
of the product attributes
Measureability of the parameters is seen as very important.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
21
QUALITY FUNCTION
DEPLOYMENT
MATRIX INTERACTION
The project objectives from steps 3 are subsequently translated
into priorities for the technical parameters.
This steps form the core of the QFD method as the technical
parameters can be linked to various product attributes, in a matrix
the product attributes (what) are set off against the technical
parameter (how)
Subsequently, it is determined for each cell of the matrix whether
there is a relationship or not, and if so , what is the strength of
this relationship.The completed matrix provides the
operationalisation of the product attributes, and is tool for
determining the priority of the technical parameters
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
22
QUALITY FUNCTION
DEPLOYMENT
INTERACTION BETWEEN PARAMETERS
Changing parameters can influence one or more other
parameters.
It is important to make the nature and strength of these
interaction explicit before generating solution to improve one or
more specific parameters of the product.
In a second matrix, the so called “the roof of the House of
Quality” the interaction between the parameters can be laid down.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
23
QUALITY FUNCTION
DEPLOYMENT
TECHNICAL ANALYSIS AND TARGET VALUES
The current product and competitive products are being analysed
to established the parameter values of various products.
This comparison provides an insight into the possibility for
improvement of the product and can help to set target values to be
pursued.
The inventory of possible improvement also provides a test for
consistency of interaction matrix and the project objectives as it
must be possible to align the results of the technical analysis
through the interaction matrix with the results of product
evaluation
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
24
QUALITY FUNCTION
DEPLOYMENT
FEASIBILITY
In general, one will seek improvement of those parameters for which the
competitive products score better than the own product.
The feasibility, however, of an improvement depends on the knowledge and
skills of the people in the organisation, the available development capacity and
the available production process.Therefore it is useful to estimate the degree of
complexity or the costs of an improvement
Finally, based on the priorities, feasibility and the mutual relationship between
parameters, it has to be decided on which parameter and target values in the
product development project will focus
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
25
QUALITY FUNCTION
DEPLOYMENT
DEVELOPMENT PLAN
The final results of QFD method is a development plan for the
product involved.
This plan lays down the target values(requirement) for technical
parameters and is tailored to the development capacity available
for the project.
Parameter which because of feasibility do not yet qualify for
improvement can give direction to R&D activities in the long term
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
26
CASE 1 : OF QFD
APPLICATION OF QFD ON ATTACHE CASE
The case is based on fictional problem : the improvement of an
attache case,
The example served as an illustration only, not every steps is
worked in detail
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
27
CASE 1 : OF QFD
APPLICATION OF QFD ON ATTACHE CASE
The case is based on fictional problem : the improvement of an
attache case,
The example served as an illustration only, not every steps is
worked in detail
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
28
CASE
1. CUSTOMER VOICE :
Determine what the customer considers important in a case
By Mean-end analysis attributes can be refined
Weighing factors shows the relative importance of product
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
29
CASE
1. CUSTOMER VOICE :
Product Attributes
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
Dr A. Riza Wahono :
Product Development
Importance
2
4
4
1
3
5
3
2
“ Qualitas krn Desain ”
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CASE
2. PRODUCT EVALUATION:
•
•
•
A systematic comparison of our product
with that of our competitor in the eye of
our customers
The product evaluation shows the
potential improvement of our product
Strong and weak point of our design
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
31
CASE
2. Product Evaluation:
Product Attributes
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
1
Our Product
Dr A. Riza Wahono :
Product Development
2
3
4
5
Competitive Product
“ Qualitas krn Desain ”
modul 5
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CASE
3. Project Objectives:
•
•
•
•
•
Determining the aspects to improve involves strategic choices
for relative importance of the product attributes
For attributes which do not need improvement, the target
value is equal to the evaluation score of current product
The improvement rate relates the desired improvement to the
current performance
Improvement rate = target value/evaluation score
Weight of each product is calculated
Weight = importance x improvement rate
Normalising the weighing scores into percentage
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
33
3
4
5
Weight (%)
2
Weight
Product Attributes 1
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
Improvement Rate
3. Project Objectives:
Target Value
CASE
4 1 2 6
5 1.7 6.8 20
5 2.5 10 30
4 1 1 3
4 1.3 3.9 12
4 1 5 15
4 1 3 9
3 1 2 6
33.7 100
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
34
CASE
4. Technical Parameters:
• Voice of the Engineers
• Translate the subjective customers statement into objective
engineering performance measure
• QFD team must create a lists of technical measurement that
are most likely to predict the degree to which a need will be
fulfilled (Mean-End hierarchy)
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
35
CASE
4. Technical Parameters:
- Volume
- Safety Lock
- Empty Weight
- Opening Steps
- Segment
- Material
- Angle of Opening
- Closing force
- Wear of lock
Dr A. Riza Wahono :
394 cm3
Type X
2.4 Kg
6 steps
5 segment
Type K
80 degree
0.045 N
5000 cycle
Product Development
“ Qualitas krn Desain ”
modul 5
36
CASE
5. Matrix Interaction :
•
Relation between the product attributes and technical
parameter are investigated
• How strong is the relation for each cell
• A score of importance or the parameter-attribute is obtained by
Score = Strength of relationship x weight of attribute
• The sum of these scores per column indicates the priority of the
technical parameters for the project
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
37
Strong relationship = 9
Medium Relationship =3
Weak Relationship = 1
Product Attributes
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
Sum Scores
Priority (%)
Dr A. Riza Wahono :
54
6
60
9
135
108
36
45
135
135
3
5
3
9
18
54
1
9
9
27
27
4
90
36
15
4
60
20
270
30
2
6
138
150 57
333 305
150 99
153 231
1616
9
9
21
9
9
100
4
Product Development
19
6
20
30
3
12
15
9
6
2
6
180
27
Importance
6
14
“ Qualitas krn Desain ”
Weight (%)
Technical Parameters
- Volume
- Safety Lock
- Empty Weight
- Opening Steps
- Segment
- Material
- Angle of Opening
- Closing force
- Wear of lock
5. Matrix Interaction
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6. Interaction Between Technical Parameters:
• Technical trade-offs
• If one technical feature is improved, is there a strong
possibility that another will also improve ? If yes then
POSITIVE correlation exists
• Alternatively, If one technical feature is improved, is there
a strong possibility that another will get worse ? If yes then
NEGATIVE correlation exists
• Knowing the relationship and the priority for each technical
parameter the company must approach the conflict as an
opportunity for technical breakthrough.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
39
6. Interaction Between Technical Parameters:
Technical Parameters
- Volume
- Safety Lock
- Empty Weight
- Opening Steps
- Segment
- Material
- Angle of opening
- Closing force
- Wear of lock
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
40
7. Technical Analysis and Target
• On the basis of technical parameter, another comparison and
evaluation should be carried out
• On the basis of the technical data and the priorities of the
parameter the target values are now being determined
• A group of related technical parameters with these target
values can then be submitted as PDS to a relatively
independent design assignment team of designers
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
41
Dr A. Riza Wahono :
- Segment
- Material
- Angle of Opening
- Closing force
- Wear of lock
Target Value
- Opening Steps
Competitive Product
- Empty Weight
Our Product
- Safety Lock
Measurement Unit
- Volume
Technical Parameters
7. Technical Analysis and Target
cm3
type
kg
#
#
type
deg
N
#
394
x
2.4
6
5
k
80
0.45
5000
416
y
2.2
4
6
l
85
0.32
3500
394
x
4
2
8
k
80
0.45
5500
Product Development
“ Qualitas krn Desain ”
modul 5
42
9. Development Plan :
•
The design team will have to pay attention to the factor that
will improve the overall quality of product
• In this case of attache case, the designer need to work on
• reducing the the steps necessary to open the case to a
target value of 2.
• Increasing the segment into 8
• and increasing the wearnes of the lock to 5500 cycles.
Dr A. Riza Wahono :
Product Development
“ Qualitas krn Desain ”
modul 5
43
54
180 20
60
30
27
9
18
6
150
57
333
305
150
Priority (%)
9
9
4
21
19
9
9 14
type
kg
#
#
type
deg
N
#
394
x
2.4
6
5
k
80
0.45
5000
Competitive
Product
416
y
2.2
4
6
l
85
0.32
3500
Target Value
394
x
4
2
8
k
80
0.45
5500
Product Development
Weight (%)
1
2
6
33.7
100
5
6
Weight
3
45 135
231
Improvement Rate
2
3
99 153
Target Value
9
108 36
cm3
Our Product
3
1
138
Measurement Unit
3
5
4
4
4
4
9
27
5
4
5
4
9
135
4
6
20
30
3
12
15
4
15 135
3
2
6.8
10
1
3.9
5
90
36
54
- Wear of lock
60
2
1
1.7
2.5
1
1.3
1
1
270
9
27
1
2
6
6
Sum Scores
Dr A. Riza Wahono :
- Closing force
- Angle of Opening
- Material
- Segment
- Opening Steps
- Empty Weight
- Safety Lock
- Volume
Product Attributes
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
Technical Parameters
HOUSE OF QUALITY
1616
100
“ Qualitas krn Desain ”
modul 5
44
WHAT
54
27
54
138
Priority (%)
9
18
6
150
57
333
305
150
9
4
21
19
9
99 153
6
Dr A. Riza Wahono :
Weight (%)
9
2
3
1
2
6
33.7
100
9 14
1616
100
type
kg
#
#
type
deg
N
#
394
x
2.4
6
5
k
80
0.45
5000
Competitive
Product
416
y
2.2
4
6
l
85
0.32
3500
Target Value
394
x
4
2
8
k
80
0.45
5500
Product Development
Weight
3
COMPETITIVE
ASSESMENT
IMPORTANCE RATING
Our Product
Improvement Rate
3
5
4
4
4
4
231
cm3
Measurement Unit
Target Value
- Wear of lock
- Closing force
9
5
6
20
30
3
12
15
1
9
9
9
RELATIONSHIP
3
108 36
36
MATRIX
15 135
45 135 5
135
27
4
2
6.8
10
1
3.9
5
4
90
270
3
1
1.7
2.5
1
1.3
1
1
4
60
2
4
5
2
180 20
30
Sum Scores
1
6
6
60
27
- Material
- Segment
HOW
- Angle of Opening
- Safety Lock
- Empty Weight
- Opening Steps
CORRELATION
MATRIX
- Volume
Product Attributes
- Easy to carry
- Easy to open
- Easy to find contents
- Adjustable capacity
- Easy to Close
- Durable
- Stable when standing
- Privately accessible
Technical Parameters
HOUSE OF QUALITY
HOW MUCH
“ Qualitas krn Desain ”
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45
QFD FLOW
Dr A. Riza Wahono :
Part
Characteristic
Product Development
Manufacturing
Operation
Manufacturing
Operation
Part
Characteristic
Design
Requirements
Customer
Requirements
Design
Requirements
“ Qualitas krn Desain ”
Production
Requirement
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46