1. TM 1 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Readily Accessible Fast Retrieval Able to Store Legacy Data Able to Store Legacy Data Dialog Boxes Web Based Access Function / Feature Diagram – Fast Retrieval Retrieve Specs by Part Number Retrieve Specs by Part Number Dialog Boxes Web Based Access Link to Component DRW FunctionsFunctions Features Link to Component DRW Web Based Access Fig. 4-23

2. TM 2 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Minimum # Of User Inputs Minimum # Of User Inputs DRW Retrievable by Latest Revision DRW Retrievable by Latest Revision Link to Component DRW Data Sortable Searching Dialog Boxes Function / Feature Diagram – Minimum # of User Inputs Web Based Access Retrieve Specs by Part Number Retrieve Specs by Part Number Dialog Boxes Web Based Access Link to Component DRW FunctionsFunctions Features 3D Cabinet Fig. 4-24

3. TM 3 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Information is Accurate Accurate DRW Retrievable by Latest Revision DRW Retrievable by Latest Revision Link to Component DRW Data Sortable Searching Dialog Boxes Function / Feature Diagram – Information is Accurate Web Based Access Retrieve Specs by Part Number Retrieve Specs by Part Number Dialog Boxes Web Based Access Link to Component DRW FunctionsFunctions Features 3D Cabinet Fig. 4-25

4. TM 4 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill QFD Flow Down Fig. 4-26

5. TM 5 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill QFD Flow Down Fig. 4-27

6. TM 6 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Design Scorecard Fig. 4-27a

7. TM 7 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Verification CTQ Capability Analysis Drawing Access Spec (combined data from Dim and Non- Dim Lookup) Alpha: 0.05 Ho: Data is Normal Ha: Data is not Normal P-value: <0.005, therefore reject Ho. Data is Not Normal. Perform Levenes test for equal variance Conclusion: Use Mann -Whitney for data statistical analysis Conclusion: Baseline capability based on 0 DPMO is 6 sigma Fig. 4-28

8. TM 8 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Verification CTQ Capability Analysis Drawing Access Spec (combined data from Dim and Non- Dim Lookup) Customer Expectations are 1.70 minutes or faster to access and print a drawing, from CTQ Survey. Is the new system running at the customers expectations? This is the Primary CTQ on our design scorecard. Conclusion: DDL and the design of the user interface will meet customer expectations for drawing access time. Ho = Sample median is equal to 1.70 minutes Ha = Sample median is not equal to 1.70 minutes Alpha = 0.05 Ho = Sample median is equal to 1.70 minutes Ha = Sample median is less than 1.70 minutes Alpha = 0.05 P value =.002 < 0.05 Therefore reject Ho Ha = Sample median is not equal to 1.70 minutes P value =.001 < 0.05 Therefore reject Ho Ha = Sample median is less than 1.70 minutes Fig. 4-29

9. TM 9 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Design Scorecard Fig. 4-30

10. TM 10 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Finish Quality Metric - QFD Ways to measure Fig. 4-31

11. TM 11 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 5-2

12. TM 12 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 5-3

13. TM 13 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 5-9

14. TM 14 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 6-1

15. TM 15 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 6-4

16. TM 16 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 6-8

17. TM 17 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 6-11

18. TM 18 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 7-1

19. TM 19 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 9-1

20. TM 20 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 9-2

21. TM 21 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 11-4

22. TM 22 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 11-6

23. TM 23 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 11-7

24. TM 24 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 12-1

25. TM 25 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 12-2

26. TM 26 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill History of Manufacturing Craft Mass Lean Made to customer spec. Single-piece mfg. Variable quality Little inventory High cost High Quality Interchangeable parts Division of labor (Taylor system) Assembly lines (Henry Ford) Low variety (Ford) Parts per hour Focus on costs – less quality High variety Small batches PPM quality Engaged workforce Higher quality lower costs 1875 1900 1925 1950 1975 2000 Fig. 13-1

27. TM 27 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill To Product/process focus Co-location, collaboration Constant, visible communication Multi-skilling, teamwork, balance Product lines as businesses 1-piece flow or ‘Flow of value’ Lean Characteristics From Functional alignment/focus Functional ‘silos’ Weak communications Specialization Overhead allocation Slow, batch, inventory Fig. 13-2

28. TM 28 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Takt Time Calculation Example: Over 10 Days 1 2 3 4 5 6 7 8 9 10 Demand 30 40 50 60 10 30 40 20 60 40 380 Time available in period (840 min.) Average demand (38) = 22.1 minutes Based on 2 shifts of 7 hours Determine Pace Per Day: Fig. 13-3

29. TM 29 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-4a

30. TM 30 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-4b

31. TM 31 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-5

32. TM 32 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-6

33. TM 33 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-7

34. TM 34 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-10

35. TM 35 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-11

36. TM 36 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-12

37. TM 37 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-13

38. TM 38 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-13a

39. TM 39 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-14

40. TM 40 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 13-15

41. TM 41 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 14-1

42. TM 42 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-2a

43. TM 43 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-2b

44. TM 44 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-2c

45. TM 45 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-2d

46. TM 46 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-2e

47. TM 47 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Fig. 15-3

48. TM 48 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Measurement System Analysis Sheen Gage Study Gage R&R %Contribution Source VarComp (of VarComp) Total Gage R&R 0.0519 0.69 Repeatability 0.0298 0.39 Reproducibility 0.0221 0.29 Operator 0.0028 0.04 Operator*Measurement 0.0193 0.26 Part-To-Part 7.4851 99.31 Total Variation 7.5370 100.00 StdDev Study Var %Study Var Source (SD) (5.15*SD) (%SV) Total Gage R&R 0.22776 1.1730 8.30 Repeatability 0.17248 0.8883 6.28 Reproducibility 0.14874 0.7660 5.42 Operator 0.05294 0.2726 1.93 Operator*Measurement 0.13900 0.7159 5.06 Part-To-Part 2.73590 14.0899 99.66 Total Variation 2.74536 14.1386 100.00 Number of Distinct Categories = 17 Fig. 15-6

49. TM 49 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Gage R & R – Sheen Gage Fig. 15-7

50. TM 50 ©The McGraw/Hill Companies, Inc.,2006McGraw/Hill Validate Measurement System Attribute Data Analysis – MSA 1 Fig. 15-8