Design Control What Will Be Covered Definition of Design Control Technology In Design Taguchi Method Benchmarking QS 9000 Summary An overview of the powerpoint presentation.

Definition of Design Control Design Control – “A set of steps focused on managing the design of a product.” Definition taken from “Managing Quality” By S. Thomas Foster. p455

Brainstorming Exercise Think of how much money your organization spends on error correction each year. Implementing a Design Control system can cut long term costs as well as improve quality and eliminate waste. Purpose: To get viewers to think about whether or not a design control system should be implemented in their organization.

Technology In Design In today’s changing world, technologies like Computer Aided Design (CAD) have emerged as the standard tool in designing new products. Designers no longer manually design products by drawing multiple drafts and hand-building models. Virtual models are used to test products. Quality must exist in both the computer programs and the operators in order to produce a quality product design.

Brief Overview of CAD Can be used to simulate real-world situations. Multi-User CAD systems Design Review Computer Aided Inspection (CAI) Computer Aided Testing (CAT) Multi-user CAD systems allow a group of workers at different locations to work on the same project using networking which connects them to a common server containing the project. Each team or designer can make their changes independently and the system allows every designer of the product to see the changes from their location easily. Design Review allows CAD users to focus on individual parts of a design and inspect them on the computer. This allows the designer to catch any small problems that might arise after prototype production. Computer Aided Inspection. Related to design review. Allows product to be virtually inspected. Cuts costs. Computer Aided Testing allows virtual prototyping. Also reduces costs. All of the above methods and technologies allow for more accurate testing by cutting down on the human element. These technologies can also hinder product development because computers are no substitute for the human opinion.

Why Implement a CAD System? Reduce costs Improve Accuracy of Design Improve Accuracy of Testing Overall Improvement in Quality Reduce Costs. CAD systems are cheaper than hiring multiple designers and having them collaborate and come up with one design. Improvements on Testing and Design explained in previous slide. Overall improvement in quality comes through more accurate design and testing. This cuts down on costs of fixing the product later.

The Taguchi Method The Taguchi Method for quality improvement is named after Dr. Genichi Taguchi who first introduced the method at AT&T Bell Laboratories in 1980. Taguchi method is mainly a statistical theory but also address other pertinent points like robust design which will be discussed later in the presentation.

The Taguchi Method The Taguchi Definition of Quality differs from traditional definitions of quality Taguchi said Ideal Quality is delivered when “a product or service performs its intended function throughout its projected life under reasonable operating conditions without harmful side effects.” Definition of ideal quality taken from “Managing Quality” by S.Thomas Foster

The Taguchi Method Robust Design products should be designed so that they are free of all defects and are of the highest quality.

Robust Design (The Taguchi Method) Three Step Method for Creating Robust Designs Concept Design Parameter Design Tolerance Design

Concept Design Deals with the design of the process. Properly selecting process components and methods can reduce costs and increase the quality of the finished product.

Parameter Design Deals with finding the optimal levels of variables that management can control in a process. Parameter design does not usually affect production costs, but rather attempts to find the best level of performance for the system.

Tolerance Design Refers to finding the acceptable variation limits after the parameter design has been established. Usually results in an increase in production costs, but also an increase in production quality.

Robust Design Steps In order to create a robust design, the following steps are used to incorporate the three perspectives Taguchi states.

Steps for Creating a Robust Design 1. Identify the main Function 2. Identify the noise factors and testing conditions 3. Identify the quality characteristics to be observed and the objective function to be optimized 4. Identify the control factors and their alternative levels 5. Design the matrix experiment and define the data analysis procedure 6. Conduct the matrix experiment 7. Analyze the data and determine near optimum levels for the control factors 8. Predict the performance at these levels Steps taken from http://mijuno.larc.nasa.gov/pap/robdes/robdes.html By Resit Unal and Edwin B. Dean These steps take into consideration the 3 earlier steps of Concept Design, Parameter Design, and Tolerance Design.

Benchmarking Another method that can be helpful in creating high quality designs is benchmarking. A benchmark is a company which is recognized for being the best in a certain field.

Benchmarking Companies model themselves after the benchmark corporations in their specific field. The initiator firm might contact the target firm for information and statistics to be used for improvement of both corporations.

Benchmarking There are six types of benchmarking. Process Benchmarking Financial Benchmarking Performance Benchmarking Product Benchmarking Strategic Benchmarking Functional Benchmarking Process Benchmarking. Focuses on process flows, operations, technologies. Financial Benchmarking. Compare financial records between the two firms to find a financial target. Performance Benchmarking. Speed, quality, productivity. Product Benchmarking. Sometimes includes reverse engineering the target’s product in order to improve the design of the initiator’s product. Strategic Benchmarking. Observing the competition methods of the target firm. The target firms are sometimes winners of quality awards such as the Baldrige or Deming. Functional Benchmarking. Focuses on one function of the business and how to improve that function.

QS 9000 QS9000 is a supplier development program Provides a supplier standard for auto companies QS9000 has a requirement dealing with design control

QS 9000 The Design Control Requirement of QS9000. Suppliers must be qualified in value engineering, geometric tolerance and dimensioning, and the Taguchi Method.

QS9000 – A Real World Example A team of representatives from GM, Ford and Chrysler developed the QS9000 standard, including the standard for design control. Suppliers to these auto manufactures need to be QS9000 certified. QS 9000 is a real world example of how implementing a design control system can pay off. Also an example of how design control is a basic requirement in order for a business to be recognized as a dependable supplier. Design control requirements for QS9000 General Info Design and development planning required skills Organizational and technical interfaces Design input Design output Design review Design verification Design validation Design changes

Exercise Write down the approximate annual cost of error correction and losses due to poor quality in your organization. Now calculate approximately how much a design control system such as CAD would cost to implement. A QMS/ISO9000 Design control system can cost between $10,000 and $500,000, depending on the size of the corporation. Consider that it could be free to employ the Taguchi Method and also improve quality and cut costs. Prices taken from http://manufacturing.software-directory.com/software-2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Control.ISO.9000.44.shtml This website sells the software mentioned above.

Summary Design Controls can help improve quality and cut costs. Free ideas like the Taguchi Method are harder to implement but can pay off in the end. Technology like CAD systems can also aid in design quality This slide summarizes the main important points that the viewer should get out of the presentation.

Bibliography http://mijuno.larc.nasa.gov/pap/robdes/robdes.html “DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN APPROACH.” By Resit Unal and Edwin B. Dean “Managing Quality, An Integrative Approach” By S. Thomas Foster “Plant and Service Tours in Operations Management” by Roger W. Schmenner http://manufacturing.software-directory.com/software-2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Control.ISO.9000.44.shtml QMS PROGRAMS /ISO 9000 DESIGN CONTROL (ISO 9000/4.4)