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

3. 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
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4. 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
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5. Designing Product for Quality
In design product we must first many Questions
What does it mean to design products for Quality
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6. 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)
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7. Quality Fuction Deployment (QFM)
See Figure 7-2, QFD Layout: The House of Quality:
Technical Requirements
Customer Requirements
Competitive Assigment
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8. 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
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9. 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)
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10. 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
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11. 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
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12. 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
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13. Design for Reliability
Reliability Analysis Tools
Failure Modes and Effects Analysis (FMEA)
Fault Tree Analysis
Failure Modes, Effects, and Criticality Analysis (FMECA)
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14. 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.
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15. 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.
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16. Design for Reliability
FMEA Steps
Figure 7.18
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17. 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.
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18. 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.
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19. Design for Reliability
Figure 7.20
Fault Tree Diagram
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20. 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.
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21. 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.
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22. 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.
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23. 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.
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24. 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.
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25. 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
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