1. Advanced Manufacturing Systems Design © 1999 John W. Nazemetz QFD and Concurrent Engineering Discussion Topic 5 September 14, 1999

2. © 1999 John W. NazemetzSlide 2 Computer Integrated Manufacturing Systems Concurrent Engineering Using QFD to Design a Concurrent Engineering Process -- Discussion of Assignment

3. © 1999 John W. NazemetzSlide 3 Computer Integrated Manufacturing Systems Assignment (1) Assume you are a consulting firm which develops concurrent engineering processes for client companies. Using the QFD methodology of Sullivan, develop a series of matrices for your product (i.e., develop Figures comparable to Fig 4.5, 4.6, 4.7, 4.9 (hypothesize competitors), 4.13). Note: all of these figures are cumulative so one matrix which contains all of the information will suffice.Assume you are a consulting firm which develops concurrent engineering processes for client companies. Using the QFD methodology of Sullivan, develop a series of matrices for your product (i.e., develop Figures comparable to Fig 4.5, 4.6, 4.7, 4.9 (hypothesize competitors), 4.13). Note: all of these figures are cumulative so one matrix which contains all of the information will suffice.

4. © 1999 John W. NazemetzSlide 4 Computer Integrated Manufacturing Systems Assignment (Hint) Hint: you may wish/benefit from establishing a (multi-level) hierarchical grouping of requirements, control characteristics, etc.-- this will help you in dealing with your concepts as abstract groups -- e.g., you may wish to use the abstract groupings Design, Process Planning, … and then use these to organize your thinking with respect to customer requirements, control characteristics, etc.Hint: you may wish/benefit from establishing a (multi-level) hierarchical grouping of requirements, control characteristics, etc.-- this will help you in dealing with your concepts as abstract groups -- e.g., you may wish to use the abstract groupings Design, Process Planning, … and then use these to organize your thinking with respect to customer requirements, control characteristics, etc.

5. © 1999 John W. NazemetzSlide 5 Computer Integrated Manufacturing Systems Typical Experience Theory/ProcessTheory/Process –Sounded Simple, Straight Forward ExecutionExecution –Difficult to Get Started Where to Start Needed Logical Groupings/Categories –Difficult Organizing Thoughts Coherently Formatting Response

6. © 1999 John W. NazemetzSlide 6 Computer Integrated Manufacturing Systems Customer Requirements (1) Typical Requirements (Customer Terms)Typical Requirements (Customer Terms) –More Effective Integration of Engineering Activities –Establish New Design Paradigm/Culture –Reduce Time of Design –Reduce Cost of Design –Reduce Total System Costs –Gain Competitive Advantage –Reduce Post-Release Engineering Design Changes

7. © 1999 John W. NazemetzSlide 7 Computer Integrated Manufacturing Systems Customer Requirements (2) Typical Requirements (Customer Terms)Typical Requirements (Customer Terms) –Improve Customer Satisfaction –Improve Sales/Market Share –Reduce Manufacturing Problems/Complaints –Enable Cross-Training/Discipline Appreciation –Improve Communication –…

8. © 1999 John W. NazemetzSlide 8 Computer Integrated Manufacturing Systems Final Product Control Characteristics Probably Most Difficult Part of AssignmentProbably Most Difficult Part of Assignment Need to Use Viewpoints to Organize ThinkingNeed to Use Viewpoints to Organize Thinking Need Measurable System Performance MetricsNeed Measurable System Performance Metrics

9. © 1999 John W. NazemetzSlide 9 Computer Integrated Manufacturing Systems Final Product Control Characteristics DesignDesign ProduceProduce Operate/EvaluateOperate/Evaluate Maintain/ReviseMaintain/Revise DisposalDisposal ManagementManagement Customer’s CustomersCustomer’s Customers EngineeringEngineering ManufacturingManufacturing MaintenanceMaintenance … Life Cycle Views Organizational Views

10. © 1999 John W. NazemetzSlide 10 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Design 1) DesignDesign –Method Assures All Views Heard Structured Group Processes Sensitivity Training Effective Facilitors … –Method Assures All Views Considered Value Engineering Design for Manufacturing Design for Assembly …

11. © 1999 John W. NazemetzSlide 11 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Design 2) DesignDesign –Appropriate Design Tools/Aids Identified and Made Available CAD System Evaluation and Selection CAPP System Design, Evaluation, Specification Group Technology Design, Evaluation, Implementation –Method Assures Adequate Training Available –Method Assures Training Taken/Learned –…

12. © 1999 John W. NazemetzSlide 12 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Produce 1) ProduceProduce –Infrastructure Investment –Customization Expenses/Reusability –Documentation/Tool Development –Skills/Personnel Acquisition –…

13. © 1999 John W. NazemetzSlide 13 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Operate ) Operate/AssessOperate/Assess –Production Start-up Problems Contingency Funds Allowed/Spent per Project (Measure of Risk/Uncertainty) –Number of Engineering Changes –Number of Personnel/Cost –Mean Time –to Product Design Re- Engineering/Overhaul –Information Gathering/Exchange Costs –…

14. © 1999 John W. NazemetzSlide 14 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Maintain) MaintainMaintain –Recurring Consulting Fees/Visits –Personnel Re-Training Costs –Equipment/Tool/Method Change/Replacement Mean Time to Change/Replacement Mean Time to Re-Organization of Function Cost of Abandoned Tools/Practices –…

15. © 1999 John W. NazemetzSlide 15 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Disposal) DisposalDisposal –Mean Time for Displaced Personnel to Find New Position –Separation/Re-Training Costs –Lost Training Investment –Loss of Customer’s Customer Confidence –…

16. © 1999 John W. NazemetzSlide 16 Computer Integrated Manufacturing Systems Final Product Control Characteristics (Management) Management ViewManagement View –Cost to Develop –Marketability –Time to Develop Product –Time to Deliver Product –…

17. © 1999 John W. NazemetzSlide 17 Computer Integrated Manufacturing Systems Relationships Map Final Product Control Characteristics and Customer RequirementsMap Final Product Control Characteristics and Customer Requirements Hypothesize Markets, TargetsHypothesize Markets, Targets IterateIterate

18. © 1999 John W. NazemetzSlide 18 Computer Integrated Manufacturing Systems Example Solutions - Observations Example 1Example 1 –Analysis Performed at Higher Level of Abstraction Example 2Example 2 –More Detailed (More Rows, Columns) BothBoth –Scope/Coverage Very Similar –Details of Example 2 Map into Example 1 –Final Product Control Characteristics Not Quantitative

19. Advanced Manufacturing Systems Design © 1999 John W. Nazemetz QFD and Concurrent Engineering Discussion Topic 5 September 14, 1999