Productivity Improvement Using QFD

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Productivity Improvement Using QFD
1999-08-19 at IBQPP
Professor Hisakazu Shindo Dept. of Computer
Science Media Engineering shindo_at_kki.yamanashi.a
c.jp http//www.is.esi.yamanashi.ac.jp/shindo/
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Kofu City
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Yamanashi is the navel (center) of Japan.
Asahikawa
Kagoshima
For further information, please browse
http//www.pref.yamanashi.jp/
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Grapes and other fruits and wine
Jewelry
Sightseeing
Electronics and mechatronics
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1. What is QFD?
Deployment of Quality Traditional QFD has been
mainly applied to Quality Assurance.
Weight
Quality elements
Requirements for quality
A method to reflect users requirements into a
product by way of quality elements.
Easy to carry
specifications
A basic quality table
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Deployment of Quality Function
A method for clarifying the structure of quality
functions such as inspection, quality evaluation,
test, etc. usually in a tree diagram.
Deployment of Quality Systematically clarify
the quality itself Deployment of Quality
Function Systematically clarify the
activities necessary to attain the required
quality
QFD
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2. Two approaches to a problem solving
Guaranteed to be converged
QC story
Sometimes seemed to be divergent
QFD Work system design
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3. Engineering Drawing and Quality Table
A table like a quality table can be regarded as a
description of a product. Even if the object is
not shaped, a table-like description is
available.
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4. Reducing complexity of a description
We can describe a product, system, service, etc.
from at least two viewpoints. But, we cannot
understand its inside structure.
An example of a description
Do you understand what the table indicates?
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The more understandable table obtained by QM3
Original data
The result of the Quantification Method of Type
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Rearranged data
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The festival called Shingen-kou Matsuri
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(No Transcript)
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5. Applying QFD to problem solving from a
design-oriented viewpoint
1. Describe the problem Extract factors which
constitute the problem Determine how to
describe the problem by combining factors
(What are the top-view, front-view, side-view,
etc.?) 2. Fulfill the each table and their
relationship If the table is difficult to
understand, try to reduce complexity and
summarize the features 3. Set the target value
to be realized Notice the gap between target
and actual values Authorize the major
bottlenecks 4. Develop ideas to overcome the
bottlenecks An optimum countermeasure is
sometimes selected by AHP 5. Plan to carry out
the optimum countermeasure Extract necessary
tasks to be allocated to members Scheduling
methods help us shorten the period of
realization Set milestones to manage the
process 6. Check the progress of the project, and
take an action if necessary 7. Confirm the target
values are realized 8. Share the knowledge
among members obtained through the project
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6. How to improve productivity
Statements of the problem
(0) Productivity improvement This is a
slogan. It cannot be completely solved. (1) Why
cant we improve the productivity?
This is a general expression. The policy to solve
the problem should be determined. (2)
Why is the productivity unstable? This
is a problem not of the average but of the
dispersion. (3) What are the obstructive factors
to improving the productivity? This
is more specific problem conscious. Analytic
approach can be applied. (4) How can
we improve the productivity? This
contains two kinds of situation. A
design-oriented approach is applied in many cases.
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(A) Analytic approach (Traditional approach)
(1) Define the productivity in specific terms
(2) Extract obstructive factors to productivity
and clarify their relationship The
association diagram is helpful to describe.
DEMATEL method is sometimes effective to
analyze the diagram. (3) Grasp the critical
mechanisms Be aware of feedback from the
result to its causes. (4) Consider how to
solve the criticality (5) Select the optimum
countermeasure to improve the productivity (6)
Confirm the result, and share the obtained
knowledge
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(A) Analytic approach (Traditional approach)
(1) Define the productivity in specific terms
There are various productivity indexes,
each of which is used with a slightly
different meanings. Therefore, it is
important to define the index in which the real
situation is reflected (2) Extract
obstructive factors to productivity and clarify
their relationship The association
diagram is helpful to describe. DEMATEL method
is sometimes effective to analyze the
diagram.
Less education budget
It is difficult to identify the real cause
because of confounding of factors.
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DEMATEL(Decision Making, Trial and Evaluation
Laboratory) Method
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1
3
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Direct influence matrix
Normalized one
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Normalized direct influence matrix
Total influence matrix
No. Row sum Column sum Inf. Cor. 1,
1.19 2.04 -0.85 3.22 2,
2.56 1.01 1.54 3.57 3,
1.21 1.34 -0.13 2.55 4,
1.90 1.01 0.90 2.91 5,
2.07 1.39 0.68 3.46 6,
1.09 3.08 -1.98 4.17 7,
1.05 1.20 -0.15 2.24
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(3) Grasp the critical mechanisms
It is difficult to solve the problem because
there exists a feedback path from the result
to its cause.
(2)Lack of training
(4)Unskilled work
(5)Many defectives
(3)Machine stops
(7)Much rework
(1)Less education budget
(6)Low productivity
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(4) Consider how to solve the criticality
Reducing defectives is necessary to
improve productivity. Identify the weak
skills after analyzing defectives and make a
training plan. (5) Select the optimum
countermeasure to improve the productivity (6)
Confirm the result, and share the obtained
knowledge
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B. Design oriented approach 1. Describe the
problem Problem Productivity is low.
Extract factors which constitute the problem
Factors deeply related to productivity
Function, Processes,Equipment, Skills,
Workers, Managerial tools
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Describe the problem as follows
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2. Fulfill the each table and their relationship
If the table is difficult to understand, try
to reduce complexity and summarize the
features
In this case it seems that the reduction of
complexity is not necessary.
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3. Set the target value to be realized Notice
the gap between target and actual values
Authorize the major bottlenecks
Target values
Skills
Processes
Equipment
Workers
Function
Workers
Target values
Extract the specific bottlenecks considering the
gap between target and actual values.
Benchmarking is effectively utilized.
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4. Develop ideas to overcome the bottlenecks
An optimum countermeasure is sometimes
selected by AHP
Select the optimum
Items for evaluation
Alternatives
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5. Plan to carry out the optimum countermeasure
Extract necessary tasks to be allocated to
members Scheduling methods help us shorten
the period of realization Set milestones to
manage the process 6. Check the progress of the
project, and take an action if necessary 7.
Confirm if the target values are realized 8.
Share the knowledge among members obtained
through the project