Quality in Product and Process Design Pertemuan 13-14 Matakuliah : Perancangan Manajemen Mutu Tahun : 2009 Quality in Product and Process Design Pertemuan 13-14

Chapter 7: Quality in Product and Process Design Reference: S. Thomas Foster, “Managing Quality: An Integrative Approach”, Second Edition, Pearson Prentice Hall, New Jersey, 2003 Bina Nusantara University

Quality in Product and Process Design Designing Product for Quality Quality Fuction Deployment (QFM) Technology in Design Prototyping Methodologies Design for Reliability Environmental Consideration in Design Discussion and Questions Bina Nusantara University

Designing Product for Quality In design product we must first many Questions What does it mean to design products for Quality Bina Nusantara University

Project Development Process Product idea generation Customer future needs projection Technology selection for product Technology development for process selection Final product definition Product market and distributioaration Product design and evaluation Manufacturing system design Product manufacture, delivery and use (See Figure 7-1, Project Development Process) Bina Nusantara University

Quality Fuction Deployment (QFM) See Figure 7-2, QFD Layout: The House of Quality: Technical Requirements Customer Requirements Competitive Assigment Bina Nusantara University

The Steps in Performing a QFD Develop a list customer requirement Develop a list of technical design elements along the roof of the house Demonstrate the relationships between the customer requirements and technical design elements. Perform a competitive assessment of the customer requirements Prioritize customer requirements Prioritize technical requirements Final evaluation Bina Nusantara University

Technology in Design Computer Aided Design (CAD) system Multiuser CAD Systems Geometric Modeling Engineering Analysis Design Review Interface Checking Group Technology Computer Aided Inspection (CAI) Computer Aided Testing (CAT) Bina Nusantara University

Prototyping Methodologies Organizing the Design Team The Product Life Cycle Product Families and the Product Life Cycle (See Figure 7-13, Cumulatives Product Family Life Cycle) Complementary Products Design for Manufacture (DFM) Design for Maintenability Bina Nusantara University

Design for Reliability Failure Modes and Effects Analysis (FMEA) Improvement of the safety, quality, and the realibility of product Improvement of a company’s image and its competitiveness Increased satisfaction from user standpoint Reduction in product development cost Record of actions taken to reduce a product risk Bina Nusantara University

FMEA Steps Assign each component an identifier List functions for each part List one or two failure modes for each fuction Describe effects of each failure mode Determine hazards likelihood and catagorieze Estimate likelihood of failure Estimate failure detection Identify hightest risk Elimanate or reduce highest risk Bina Nusantara University

Design for Reliability Reliability Analysis Tools Failure Modes and Effects Analysis (FMEA) Fault Tree Analysis Failure Modes, Effects, and Criticality Analysis (FMECA) Bina Nusantara University

Design for Reliability Failure Modes and Effects Analysis (FMEA) Method for systematically considering each component of a system, identifying, analyzing, and documenting the possible failure modes within a system and the effect of each failure on the system. Benefits of FMEA Improvement of product safety, quality, and reliability. Improvement of a company’s image and competitiveness. Increased satisfaction from a user standpoint. Reduction in product development cost. Record of action taken to reduce a product risk. Bina Nusantara University

Design for Reliability Basic areas where FMEA can be applied Concept: FMEA is used to analyze a system or its subsystems in the conception of the design. Process: FMEA is applied to analyze the assembly and manufacturing processes. Design: FMEA is used for analysis of products before mass production of the product begins. Service: FMEA is used to test industry processes for failure prior to their release to customers. Equipment: FMEA can be used to analyze equipment before the final purchase. Bina Nusantara University

Design for Reliability FMEA Steps Figure 7.18 Bina Nusantara University

Design for Reliability Fault Tree Analysis An analytical tool that graphically renders the combinations of faults that lead to the failure of the system. This technique is useful for describing and assessing the events within a system. Primary Symbols of Fault Tree Analysis Events Gates Link the faults to the undesired events within the diagram. Gates show how faults are related. Bina Nusantara University

Design for Reliability Types of Events (in Fault Tree Analysis) Basic events are initiating faults that do not require events below them to show how they occurred. The symbol used for a basic event is a circle. An intermediate event is the result of a combination of faults, some of which may be primary events. This intermediate event is located in the middle of a fault tree. These events are described by rectangles. An expanded event requires a separate fault tree because of its complexity. For this new fault tree, the expanded event is the undesired event and would be located at the top of the fault tree. Bina Nusantara University

Design for Reliability Figure 7.20 Fault Tree Diagram Bina Nusantara University

Design for Reliability Steps in Fault Tree Analysis Become familiar with the system. Define the undesired events of the system with the related contributing and initiating events. Develop fault trees for the undesired events. Obtain probabilities for the events on the fault trees. Evaluate fault trees. Analyze the results and proposals for system improvement. Change the fault trees to reflect proposed improvements and renewed fault tree evaluation. Perform a worst case analysis. Bina Nusantara University

Design for Reliability Failure Mode, Effect, and Criticality Analysis (FMECA) An extensive, but simple method for identifying ways in which an engineered system could fail. Criticality In FMECA is important because it prioritizes how the design team should be spending its resources. In general, criticality refers to how often a failure will occur, how easy it is to diagnose, and whether it can be fixed. Critically assessment is somewhat subjective because it depends on the viewpoint of a service or field analysis. Bina Nusantara University

Design for Reliability Product Traceability The ability to trace a component part of a product back to its original manufacturer. Consumer Product Safety Commission (CPSC) An independent federal regulatory agency that helps keep American families safe by reducing the risk of injury or death from consumer products. Bina Nusantara University

Environmental Conditions in Design Importance Currently, society demands much more from product designers than just high-quality products. Many manufacturers have turned to a more environmental form of manufacturing that offers positive returns on investment. Green Manufacturing Movement that began in Germany with requirements for importers to remove packaging materials. Bina Nusantara University

Environmental Conditions in Design Design for Reuse Designing products so they can be used in later generations of products. Design for Disassembly A method for developing products so that they can easily be taken apart. Design for Remanufacture A method for developing products so that they parts can be used in other products. Associated with green manufacturing. Bina Nusantara University

Discussion and Questions Case 7-1: Designing the Ford Taurus: Why Quality Had to be Job 1 Case 7-2: Nucor Corporation: Producing Quality Steel by Stressing Sound Management Practices Bina Nusantara University