PRESENTED BY: Navjot Sandhu The Innovator’s Toolkit- Techniques and tools for optimizing and finalizing designs

Agenda  Objectives  Process Capability  Predict the performance of your new solution  Robust Design  Make your design insensitive to uncontrollable influences  Design Scorecards  Develop a dashboard to track your design and its underlying processes  Discrete Event Simulation  Visualize and test your innovation through computer modeling

Agenda  Rapid Prototyping  Make a fast 3D model of your solution to explore its viability

Managerial challenge  Streamlining a products creation process to meet upper management demands, customer demands, and engineering guidelines  Create an infrastructure so products can be designed and tested quickly using repeatable processes and tools

Objective  Use tools to produce a design into a workable model that can be tested, while tracking changes and progress

Agenda  Objectives  Process Capability  Predict the performance of your new solution  Robust Design  Make your design insensitive to uncontrollable influences  Design Scorecards  Develop a dashboard to track your design and its underlying processes  Discrete Event Simulation  Visualize and test your innovation through computer modeling

Process capability  Engineers need to compare how well a design meets it’s performance expectations.  In the realm of innovation, we want to focus on predictive use.  Helps improve designs

Process capability - Steps  1. Determine specifications Come from customers, engineering calculations, or pre-evaluation Make sure specifications are clear and unbiased  2.Collect Appropriate Data Quantitative data – Can be either short or long term (variable data or numbers) Qualitative data- yes/no, a particular color

Process capabilities - steps  3.Calculate Capability Metrics Measure for central tendency’s Helps to determine where the specifications of a product should lie  4.Improve the Design or Process Make it more robust to input variation Tighten tolerances of specifications and its related processes for better performance

Process capabilities Moment of truth Discussion Examples  Bank is testing a new a kiosk for that provides customers with rapid approvals on refinancing mortgages Measure customer reactions between request/information received – determined information should be displayed within 2 minutes. They expect.6 percent of customers to have wait time more than 2 minutes. If pressured with competition, they can redesign the kiosk to provide more information such as credit score, dollar amount of loan, etc…

Agenda  Objectives  Process Capability  Predict the performance of your new solution  Robust Design  Make your design insensitive to uncontrollable influences  Design Scorecards  Develop a dashboard to track your design and its underlying processes  Discrete Event Simulation  Visualize and test your innovation through computer modeling

Robust design  Helps reduce sensitivity of the innovation to uncontrollable noise variables.  Variation will occur through the lifecycle of the design through normal wear and tear.  Robust design helps predict the undesired behaviors of a design to minimize customer disappointment.

Robust design  In order to do this you need help from an experienced engineer and also have to know about the following techniques:  Performance and Perception Expectations  Axiomatic Design  Matrices of customers needs.  Design FMEA (Design Failure Mode and Effects Analysis)  Measurement of potential design errors  Design of Experiments  Design of all information gathering exercises where variation is present

Robust design - Steps  1.Identify Customer Expectations  2.Develop Conceptual Design  Create a high level design  3.Identify Control Factors and Noise Variables  4.Identify Potential Deterioration  Normal wear and tear, component wear down  5.Experiment and Determine Optimum Design  6.Determine Detailed Design Tolerances  Determine specifications that the design needs to operate within

Robust Design Moment of Truth Discussion Examples

Agenda  Objectives  Process Capability  Predict the performance of your new solution  Robust Design  Make your design insensitive to uncontrollable influences  Design Scorecards  Develop a dashboard to track your design and its underlying processes  Discrete Event Simulation  Visualize and test your innovation through computer modeling

Design scoreCards  Helps keep track of changes and progress  System Performance – Predicts how the overall design will perform against its expectations  Component Performance-Predicts of the performance of individual key components that affect overall system performance  Process Performance- Predicts the overall quality level of key processes that produce the product or deliver the service.  More robust a scorecard, more likely a problem can be fixed before customer dissatisfaction occurs

Design scorecards - Steps  1. Identify the Critical Parameters of the Performance Score Card  Identify all relevant customer expectations for your design  For each expectations, identify the : i) type of variable(discrete, continuous) ii)measurement unit  Continous indicators are tracked by their mean and standard deviations  Discrete indicators are tracked by looking at their success rate

Design Scorecards - steps  2. Determine Target and Specifications Limits on Performance Parameters  Obtained from customer input, regulatory requirements, or design functional requirements  Three scenarios apply:  i) more is better  ii) less is better  iii)achieve a specific target

Design scorecards- steps  3. Predict the Performance Indicators  Predict what values the indicators should be, then these will be later compared to actual values  4. Build the Overall and Individual Component Scorecards  Identify the critical components that significantly influence the overall system performance.  Identify their critical inputs ( weight, mass, area, etc..)

Design scorecard - steps  5. Build the Overall and Individual Process Scorecards  Identify the critical manufacturing and/or service delivery processes and sub-processes  Build a score card for each critical process  6. Interpret the Scorecard  Analyze the scorecards after there is enough data on them  Determine how much and what components and processes effect the overall performance the most  Consider what improvements can be made and where

Overall system performance score card

Overall Component scorecard

Component scorecard

Overall process scorecard

Process scorecard

Design scorecards moment of truth Discussion Examples

Agenda  Objectives  Process Capability  Predict the performance of your new solution  Robust Design  Make your design insensitive to uncontrollable influences  Design Scorecards  Develop a dashboard to track your design and its underlying processes  Discrete Event Simulation  Visualize and test your innovation through computer modeling

Discrete event simulation Computer based modeling approach that allows the simulation of scenarios Saves time and money Has to be done correctly in order to model real world situations accurately

Discrete event simulation- steps  Choose software  AutoMod, SigmaFlow, ProcessModel, Arena, iGrafx  Vary in cost and features  Develop process flow  Create process maps  Include sub-processes, decision points, and queues  Assign process attributes  For each process step, enter associated attributes which could affect the process flow or outcome

Discrete event simulation - steps  Determine resources and attributes  Determine the resources of the processes and sub-processes  Determine process entities and attributes  Determine the entities and their associated attributes that will be a part of the processes  Run trial simulations  Look for deficiencies in logic

Discrete event simulations - steps  Run actual simulations  Run simulations while varying attributes and values  Verify results  Build a prototype to verify design

Discrete event simulation moment of truth Discussion Examples

Agenda  Rapid Prototyping  Make a fast 3D model of your solution to explore its viability

Rapid prototyping  Creates a 3-dimensional model of a new innovation or product design  Use this when design needs to be assessed by designers and manufacturing engineers  Need the following  CAD  Rapid Prototyping Machine

Rapid prototyping  Three techniques available  Formative  Turn raw material into the desired shape  Subtractive  Start with a large solid, then remove material to obtain desired shape  Additive  Layer material over and over until desired shape and position is acheived

Rapid Prototyping - steps  Input CAD data  Create a computer design with the correct dimensions and attributes of your prototype  Export Data into Stereolithography Files  Export CAD file into an.stl file  Select Material and Specify Process  Depending on machine, we need to select the material  Thermoplastic resins, polycarbonate, wax, powdered materials, plastics, metals  Stereolithography technique-stacks horizontal slices on top of one another

Rapid Prototyping  Create Rapid Prototype  Clean and Finish the Prototype

Rapid prototyping Discussion Examples

Lessons Learned Turning a design into a product requires patience, know how, experts, and expertise There are tools available that help cut costs, streamline processes, analyze designs, and allow for organized documentation of details Most great products need to be designed, tested, and then redesigned

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