Chapter 13 Quality by Design
Quality by Design Definition Benefits Teams Communication Models Tools Misconceptions and Pitfalls Exemplary Organizations
Definition ...practice of using a multidisciplinary team to conduct conceptual thinking, product design, and product planning all at one time. pg. 349
RUBE GOLDBERG Rube Goldberg was a bright student at the Engineering College of Berkley in California arround 1904
Benefits Faster product development Better quality Less work in progress Fewer engineering change orders Increased productivity Decreased time to market pg. 353
Teams Take advantage of existing experience Emphasize early high-quality decisions Support customer requirements Feedback constraints Efficient management of risk and change as product moves from design to sales. pg. 353
Communications Models Organizational Structure Who talks to who Straight line hierarchy (traditional) Cross-talk hierarchy (TQM structure/Information paths) pg. 356
Straight Line Hierarchy Figure 13-3, pg. 356
Cross-talk Hierarchy Figure 13-4, pg. 357
Tools TQM philosophies Computer networks ISO standards (9000 and 14000) Total Productive Maintenance Quality function deployment Information Technologies (IT) Electronic meeting software Enterprise resource planning software pg. 359
Production Tools Robotics CAD/CAM/CMC Just-in-time production Virtual planning and manufacturing software Lean Manufacturing Advanced measurement and verification pg. 356
Misconceptions and Pitfalls Not simultaneous design and production Not a “quick fix” or “magic formula” for success Does not require multiple tests of product until optimum design achieved. Not to replace or be confused with inspection protocols and programs pg. 371
Misconceptions and Pitfalls Avoid using team members improperly Avoid promises to meet unobtainable goals or schedules Avoid tight tolerances or stringent requirements for one-pass design Avoid changes in product during design phase Avoid business as usual with “low-bid” vendors Avoid automation before simplification
Exemplary Organization TRIDENT CORP
Trident Corp Founded in 1979. Manufactures precision sheet metal components, electromechanical assemblies, and custom products in medical, office-equipment, computer, and defense industries. pg. 372
Trident “Quality” “quality as a basic business plan” for both short and long term goals. Quality, cost, delivery, and service.
Trident Strategies Design quality Team efforts with partners and suppliers Regular contact with suppliers and customers Employee ownership of projects Cross-functional teams / Job diversification Acknowledgment and Reward Guarantees of Product Performance pg.373