Design For Quality and Product Excellence

Design for
Quality and
Product
Excellence
2011 Cengage Learning. All Rights Reserved. May not be scanned, copied or duplicated, or posted to a publicly accessible website, in whole or in part.
Idea
Idea
generation
generation
Concept
Concept
development
development
Product &
process design
Full-scale
Full-scale
production
production
Market
Market
introduction
introduction
Market
Market
evaluation
evaluation
Tools for Design

Development
Quality function deployment
Design for manufacturability
Design for environment and disassembly
Design for excellence
Target and tolerance design
Developing a basic functional design

involves translating customer
requirements into measurable technical
requirements and, subsequently, into
detailed design specifications.
Deploying the VOC

Technical
Requirements
Customer
Requirements
Product
Requirements
The QFD methodology has

been developed into a
continuous process, and it
can be applied equally well to
service or manufacturing
environments
Technical
Requirements
Process
Requirements
Product
Requirements
Control
Requirements
Process
Requirements
QFD benefits companies through

improved communication and
teamwork between all constituencies
in the value chain, such as between
marketing and design, between
design and manufacturing, and
between purchasing and suppliers.
The House of Quality

6
5.
5.Roof
Roof
3
4.
4.InterInterrelationships
relationships
56.
6.Targets
Targets
2 . P lannin g M atrix
1. C ustom e r
R eq uire m en ts
23.Technical
3.
Technical
Requirements
Requirements
1) Customer input
2) Technical
Specifications
3) Planning Matrix
Importance Rating
4) Relationships
What do the
customer requirements
mean to manufacturer?
5) Targets- prioritized list
of manufacturers
critical process
requirements
6) Identify the trade offs
Company B
Company A
Ergonomic design
Paint pallet
Auto exposure
Auto focus
Easy to use
G P
Reliable
F G
Easy to hold steady 2
G P
Color correction
Panel ranking
Failure 1 per 10,000
Target values
(Technical
attributes)
2 circuits
Our importance ratings 22 9 27 27 32 25
1
2011 Pearson Education
Aluminum components
G P
2 to
75%
Lightweight
0.5 A
Completed
House of
Quality
Low electricity requirements
House of Quality Example
Company A
0.7 60% yes
ok
Technical Company B
evaluation Us
0.6 50% yes
ok
0.5 75% yes
ok
5-9
Company B
Company A
Ergonomic design
Paint pallet
Auto exposure
Auto focus
Easy to use
G P
Reliable
F G
Easy to hold steady 2
G P
Color correction
Panel ranking
Failure 1 per 10,000
Target values
(Technical
attributes)
2 circuits
Our importance ratings 22 9 27 27 32 25
1
2011 Pearson Education
Aluminum components
G P
2 to
75%
Lightweight
0.5 A
Completed
House of
Quality
Low electricity requirements
House of Quality Example
Company A
0.7 60% yes
ok
Technical Company B
evaluation Us
0.6 50% yes
ok
0.5 75% yes
ok
5 - 10
Voice of the Designer
Voice of the Customer
5 - 11
5 - 12
Building the House of

Quality
1. Identify customer requirements.
2. Identify technical requirements.
3. Relate the customer requirements to the
technical requirements.
4. Conduct an evaluation of competing
products or services.
5. Evaluate technical requirements and
develop targets.
6. Determine which technical requirements to
deploy in the remainder of the
production/delivery process.
13
Identify customer
requirements
14
Identify technical
requirements
15
Relate customer
requirements to
technical
requirements
16
Conduct
competitive
evaluation
17
Develop
deployment
targets
18
19
Product design can significantly affect the

cost of manufacturing (direct and indirect
labor, materials, and overhead), redesign,
warranty, and field repair; the efficiency by
which the product can be manufactured,
and the quality of the output.
20
Design for
Manufacturability
DFM - the process of designing a product for efficient production
at the highest level of quality.

Example guidelines (see Table 12.1)
Minimize number of parts
Design for robustness
Eliminate adjustments
Make assembly easy and foolproof
Use repeatable, well-understood processes

Choose parts that can survive process operations
Design for efficient and adequate testing
Lay out parts for reliable process completion
Eliminate engineering changes
21
DFM is intended to prevent product

designs that simplify assembly operations
but require more complex and expensive
components, designs that simplify
component manufacture while
complicating the assembly process, and
designs that are simple and inexpensive to
produce but difficult or expensive
to service or support.
22
Design and Environmental

Responsibility
Design-for-Environment (DFE) - the explicit
consideration of environmental concerns

during the design of products and
processes, and includes such practices as
designing for recyclability and disassembly.
Design for disassembly
23
Design for Excellence

DFX - an emerging concept that includes many design-
related initiatives such as concurrent engineering,

design for manufacturability, design for assembly,
design for environment, and other design for
approaches
Principles
Constantly thinking in terms of how one can design or
manufacture products better

Focusing on things done right rather than things gone wrong
Defining customer expectations and going beyond them
Optimizing desirable features or results
Minimizing the overall cost without compromising quality
24

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Design For Quality and Product Excellence

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Design for

Tools for Design

Developing a basic functional design

Deploying the VOC

The QFD methodology has

QFD benefits companies through

The House of Quality

Easy to hold steady 2

Failure 1 per 10,000

Our importance ratings 22 9 27 27 32 25

Low electricity requirements

House of Quality Example

0.7 60% yes

0.6 50% yes

0.5 75% yes

Easy to hold steady 2

Failure 1 per 10,000

Our importance ratings 22 9 27 27 32 25

Low electricity requirements

House of Quality Example

0.7 60% yes

0.6 50% yes

0.5 75% yes

Voice of the Designer

Voice of the Customer

Building the House of

Product design can significantly affect the

DFM - the process of designing a product for efficient production

at the highest level of quality.

Use repeatable, well-understood processes

DFM is intended to prevent product

Design and Environmental

consideration of environmental concerns

Design for Excellence

related initiatives such as concurrent engineering,

manufacture products better

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