1. Applying Quality Deployment Ohfuji Tamagawa University

2. Examples of Quality Deployment Conceptual diagram of general quality function deployment Conceptual diagram of quality deployment for the parts manufacturer Conceptual diagram of quality deployment for the material manufacturer Conceptual diagram of quality deployment for the production goods manufacturer Conceptual diagram of quality deployment for the service sector Conceptual diagram of quality deployment for new product development Conceptual diagram of quality function deployment in a narrow sense Conceptual diagram of quality deployment for process assurance starting from the design stage Conceptual diagram of quality deployment for ISO certification Conceptual diagram of quality deployment to cope with the PL Law Conceptual diagram of technology deployment Conceptual diagram of reliability deployment Conceptual diagram of policy deployment Conceptual diagram for the retailer

3. Conceptual Diagram of General Quality Function Deployment ① Identify user demands ② Convert source data into required items ③ Convert required items into quality required by users ④ Prepare a required quality deployment table ⑤ Prepare a quality elements deployment table ⑥ Prepare a quality table ⑦ Determine the planned quality ⑧ Convert the required quality importance into the quality elements importance ⑨ Determine the quality of design

4. Figure 1 Conceptual Diagram of General Quality Function Deployment Required items Quality table ⑤ Quality elements deployment table Required quality deployment table ⑥ Identify user demands ① ② Source data Required quality ③ ⑦ Importance ⑨ Extract Quality planning Importance Quality of design ⑧

5. Conceptual Diagram of Quality Function Deployment for the Parts Manufacturer ① Select applicable parts ② Deploy applicable parts function ③ Deploy applicable parts quality characteristics ④ Prepare a two-dimensional table of parts quality characteristics and parts functions ⑤ Deploy quality characteristics of parts constituting applicable parts ⑥ Prepare a QC process chart for the production process of parts constituting applicable parts ⑦ Prepare a QC process chart for the assembly process of applicable parts. ⑧ Check the relationships between parts quality characteristics and product quality characteristics

6. Figure 2 Conceptual Diagram of Quality Deployment for the Parts Manufacturer Quality table Parts quality characteristics deployment table Quality table ② Parts function deployment table ⑤ Deployment table of quality characteristics for parts constituting the applicable parts Product quality characteristics deployment table Required quality deployment table Select applicable parts ④ ⑧ QC process chart for the production process for applicable parts QC process chart for the assembly process for applicable parts Applicable parts ① ⑥⑦

7. Conceptual Diagram of Quality Function Deployment for the Material Manufacturer ① Select applicable material ② Prepare a required quality deployment table ③ Prepare a quality characteristics deployment table ④ Prepare a two-dimensional table of required quality and quality characteristics ⑤ Prepare a material components deployment table ⑥ Prepare a two-dimensional table of quality characteristics and material components ⑦ Prepare a material production process factors deployment table. ⑧ Prepare a two-dimensional table of material components and process factors.

8. Required quality deployment table Quality table ④ ③ Quality characteristics deployment table Material components deployment table Quality table ⑥ ⑦ Material production process factors deployment table Quality table ⑧ ① Select applicable material Applicable material Figure 3 Conceptual Diagram of Quality Deployment for the Material Manufacturer

9. Conceptual Diagram of QFD for the Production Goods Manufacturer ① Select applicable production goods ② Prepare a quality characteristics deployment table for a product made of production goods ③ Prepare a production goods quality characteristics deployment table ④ Prepare a two-dimensional table of product quality characteristics and production goods quality characteristics ⑤ Deploy units and parts for applicable production goods ⑥ Prepare a quality characteristics deployment table for the unit and parts ⑦ Prepare a two-dimensional table of production goods quality characteristics and the unit and parts quality characteristics ⑧ Extract important units and parts in order to prepare a QC process chart

10. ① Quality characteristics deployment table for production goods Identify important units and parts Product made of applicable production goods Product required quality deployment table Quality table ② Product quality characteristics deployment table Units and parts deployment table for production goods Quality table ④ Select applicable production goods Applicable production goods ③ Quality table ⑦ Deploy units and parts for applicable production goods ⑤ ⑧ QC process chart Figure 4 Conceptual Diagram of QFD for the Production Goods Manufacturer

11. Conceptual Diagram of QFD for the Service Sector ① Identify the service provided ② Consider the service quality ③ Investigate the demands on the service to be provided ④ Deploy the required quality of service ⑤ Deploy service quality elements ⑥ Prepare a two-dimensional table for the required quality of service and service quality elements ⑦ Deploy a work function for providing service ⑧ Prepare a two-dimensional table for service quality elements and work function ⑨ Identify important work in order to prepare a work manual

12. Quality table ⑤ Deployment table for service quality elements Deployment table for the required quality of service Quality table Work function deployment ③ Convert ① Identify the service provided ② Consider the service quality ⑥ ⑧ Work manual ⑨ Market demands and expectations Figure 5 Conceptual Diagram of QFD for the Service Sector

13. Conceptual Diagram of QFD for New Product Development ① Investigate market demands and expectations ② Convert market demands and expectations into demand (expectations) items/strategies and extract them ③ Prepare a demand (expectation) item deployment table ④ Investigate the degree of market expectation for demand (expectation) items ⑤ Implement a comparative analysis to determine the planned quality ⑥ Generate ideas with respect to demand (expectation) items to prepare a strategy deployment table ⑦ Prepare a two-dimensional table of the demand (expectation) item deployment table and the strategy deployment table ⑧ Extract quality elements for demands and strong expectations

14. Quality table Quality elements deployment table Importance Quality of design Degree of expectation ⑦ ⑥ Strategies (ideas) deployment table Convert Convert and extract ② ① ② ⑧ Quality planning ④ ⑤ Required items deployment table ⑥ Market demands and expectations Figure 6 Conceptual Diagram of QFD for New Product Development

15. Conceptual Diagram of QFD in a Narrow Sense ① Select applicable work ② Extract the work function ③ Prepare a work function deployment table ④ Extract assurance items ⑤ Prepare an assurance items deployment table ⑥ Prepare a work function deployment table and an assurance items deployment table ⑦ Prepare a quality assurance activity list ⑧ Prepare a quality assurance system chart

16. Deployment table for work function and assurance items ⑤ Assurance items deployment table Work function deployment table ⑥ Quality assurance activity list Quality assurance system chart ⑦ ⑧ Select applicable work ① ② Applicable work Extract ④ Extract work functions Extract assurance items Figure 7 Conceptual Diagram of QFD in a Narrow Sense

17. Conceptual Diagram of QFD for Process Assurance Starting from the Design Stage ① Prepare a quality characteristics deployment table ② Prepare a production process analysis table ③ Extract process factors ④ Prepare a two-dimensional table of process factors and quality characteristics ⑤ Check the quality of design ⑥ Extract the important process ⑦ Prepare a QC process chart

18. Quality table ① Quality characteristics deployment table Required quality deployment table Quality table Process factors deployment table ③ ④ ⑥ Extract process factors ② ⑤ Quality of design Extract the important process ⑦ QC process chart Figure 8 Conceptual Diagram of QFD for Process Assurance Starting from the Design Stage

19. Conceptual Diagram of Quality Deployment for ISO Certification ① Study ISO series ② Deploy the requirements of ISO 9000 ③ Extract the work functions for QA ④ Prepare a work functions deployment table ⑤ Extract quality assurance items ⑥ Prepare a two-dimensional table of work functions and quality assurance items ⑦ Prepare a two-dimensional table of the work functions deployment table and the ISO requirements deployment table

20. Figure 9 Conceptual Diagram of QFD for ISO Certification Quality table ④ Work functions deployment table Assurance items deployment table Quality table ISO requirements deployment table Extract work functions ③ Extract ⑤ Determine which ISO series certification will be acquired ① ISO 9000 series ⑥ ⑦

21. Conceptual Diagram of Quality Deployment to Cope with the PL Law ① Organize past defects ② Deploy situation to predict defects ③ Speculate on causes for defects ④ Prepare a relation diagram for causes to extract primary causes ⑤ Prepare a two-dimensional table of defects (phenomenon) and primary causes ⑥ Prepare a two-dimensional table of primary causes and secondary causes ⑦ Plan countermeasures in terms of hardware, software, and warning labels. ⑧ Prepare a two-dimensional table of causes and countermeasures ⑨ Prepare action plans for the established countermeasures

22. Figure 10 Conceptual Diagram of QFD to Cope with the PL Law ① ⑦ Quality table ④ Primary causes deployment table Quality table Secondary causes deployment table ⑤ ⑥ Quality table Instruction Measures in terms of software Measures in terms of hardware Warning labels ⑧ Relation diagram Estimate causes ③ ⑨ Action plan Past defects Situation deployment Defects deployment table

23. Conceptual Diagram of Technology Deployment ① Select applicable company ② Deploy applicable technology ③ Deploy action ④ Prepare a technology deployment table ⑤ Check the deployment table prepared using another deployment table

24. Figure 11 Conceptual Diagram of Technology Deployment Extract technology ② ⑤ Required quality deployment table Technology and required quality deployment table Technology deployment table ⑤ Quality characteristics deployment table Select applicable company ① Applicable company ③ Applicable technology deployment table Action deployment table Technology and quality characteristics deployment table

25. Conceptual Diagram of Reliability Deployment ① Prepare an FT table ② Prepare an FT table and a required quality deployment table ③ Prepare an FT table and a parts deployment table ④ Extract the important parts ⑤ Prepare an FMEA table

26. Figure 12 Conceptual Diagram of Reliability Deployment Extract important parts Prepare an FMEA table ④ ⑤ Prepare an FT table ① Past defects FT table FT and required quality deployment table Required quality deployment table Prepare an FT table Parts deployment table ② ③ FT and parts deployment table

27. Conceptual Diagram of Policy Deployment ① Check higher level policy ② Deploy targets ③ Deploy strategies ④ Prepare a matrix of targets and strategies ⑤ Check consistency with higher level policy

28. Figure 13 Conceptual Diagram of Policy Deployment Matrix of targets and strategies Extract strategies Check higher level policy ① Higher level policy ⑤ ② Targets deployment table Strategies deployment table Extract targets ④ Check consistency with higher level policy

29. Conceptual Diagram for the Retailer ① Conduct market demands deployment ② Conduct substitute characteristics deployment ③ Translate market demands into the perceptions of suppliers ④ Implement comparative analysis to determine the target quality ⑤ Implement work functions deployment ⑥ Establish important work in order to realize the target quality ⑦ Implement management demands deployment (i.e., Results) ⑧ Deploy control items for the manager (i.e., Causes)

30. Conceptual Diagram for the Retailer ⑨ Establish control items to achieve management objectives ⑩ Implement comparative analysis to determine control targets ⑪ Identify relationships between the internal quality of conformance and market demands ⑫ Establish important work functions to realize control targets ⑬ Deploy the abilities and consciousness required of managers ⑭ Identify relationships between the work functions and abilities/consciousness required of managers ⑮ Deploy training methods to enhance abilities/consciousness ⑯ Establish training methods effective for enhancing abilities/consciousness

31. ④ ③ Required quality ② Quality characteristics ⑪ ⑩ ⑨ Management demands ⑧ Control characteristics ⑥ Work functions ⑫⑭ ⑬ Abilities and consciousness ⑯ Training methods QFD for Enhancing the CS and Abilities of Retailer Managers Figure 14 Conceptual Diagram for the Retailer

32. Figure 15 Conceptual Diagram of Quality Deployment Based on Specifications for the Parts Manufacturer Determine the quality of design Specifications and comparative analysis Extract ①② ③ ④ ⑤ ⑥ ⑦ Specifications deployment Required quality

33. Figure 16 Conceptual Diagram of Quality Deployment Based on Functions for the Parts Manufacturer Determine the quality of design Extract ① ② ③ ④ ⑤ Functions deployment Quality characteristics

34. Figure 17 Conceptual Diagram of Quality Deployment for the Parts Manufacturer in Consideration of the Cooperative System with the Customer Determine the quality of design ① ② ③ ④ ⑤ ⑥ QA table, Parts drawings Assurance net ⑦ ⑧ Quality characteristics Customer demands Units and parts

35. Assurance Net (before improvement) Parts attached the wrong way round Wrong parts installation Insufficient screw tightening Damage Defective color tone Paint removal Mask damage Parts installation missed Material acceptance Injection molding Mask setting Paint drying Appearance inspection Lens installation ×× installation Pre-delivery inspection Maintain present assurance level Quality Process Defects △ ★★ ★ ☆ ★★☆★★ ★★ ★★ ★ ★★ ○ △ × × × △ × ★ ☆ ： Sufficient FP ： Sufficient ： Insufficient ： Not expected ： Continuous ： Discontinuous Defect shipment prevention Defect occurrence prevention Type of occurrence Category Evaluation ① ② ③ ④ ① ① ①

36. No preventive action is taken other than pre-delivery inspection against highly probable defects such as missed parts installation and wrong parts installation. Problems and Countermeasures in Quality Assurance Though damage can occur in many processes, it is checked in only two processes. As many as eight types of defects have to be checked in the pre-delivery inspection, which makes it impossible to do in a given line tact time. 100% inspection is carried out to detect defects that can be detected by regular inspection for continuous occurrence. Strengthen FP. Add processes to check quality Properly allocate inspection items to adequate processes. Standardize inspection methods. Review inspection methods. Countermeasure for improvement ProblemsItem ① ② ③ ④ Source: Raise the degree of quality assurance using ‘Assurance Net’ by Yasuhiko Seki

37. Assurance Net (after improvement) ○ ★★ ★ 100% inspection ☆ ★★☆ FF ★★ ★★ ★★ ★ ★★ Sampling inspection ○ ○ ○ ○ ○ ○ ○ ★ ☆ ： Sufficient FP ： Sufficient ： Insufficient ： Not expected ： Continuous ： Discontinuous Defect shipment prevention Defect occurrence prevention Type of occurrence Category Evaluation Parts attached the wrong way round Wrong parts installation Insufficient screw tightening Damage Defective color tone Paint removal Mask damage Parts installation missed Quality Process Defects Material acceptance Injection molding Mask setting Paint drying Appearance inspection Lens installation ×× installation Pre-delivery inspection Maintain present assurance level 100% inspection Sampling inspection

38. How to Prepare a Conceptual Diagram Step 1: Clarify the objective for implementing quality deployment Step 2: Select the deployment tables (or lists) that are needed to achieve the objectives Step 3: Consider the combination of the selected deployment tables (or lists) for achieving the objectives. Step 4: Consider the two types of deployment table needed for constructing the two-dimensional table. Step 5: Summarize the results of a series of considerations in a schematic representation using triangles and squares. There are several types of conceptual diagrams depending on the objective. A conceptual diagram, however, can generally be constructed as follows:

39. Units and parts deployment table Functions deployment table Mechanism deployment table Figure 4.1 Conceptual Diagram for Working out a Specific Product from Functions

40. Work functions deployment table Required quality deployment table Quality characteristics deployment table Figure 4.2 Conceptual Diagram I for Identifying Work for Realizing Required Quality Quality characteristics weight Required quality weight Work functions weight

41. Figure 4.3 Conceptual Diagram II for Identifying Work for Realizing Required Quality Technology deployment table Quality characteristics weight Required quality weight Technology weight Work functions weight Work functions deployment table Required quality deployment table Quality characteristics deployment table

42. Figure 4.4 Conceptual Diagram for the Parts Manufacturer in Consideration of the Cooperation System with the Customer Units and parts deployment table Customer demands deployment table Quality of design definition table Customer demands weight QA table, Parts drawings Assurance net Quality characteristics deployment table