Design Control What Will Be Covered

1
Design ControlWhat Will Be Covered

• Definition of Design Control
• Technology In Design
• Taguchi Method
• Benchmarking
• QS 9000
• Summary

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Definition of Design Control

• Design Control A set of steps focused on
  managing the design of a product.

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Brainstorming Exercise

• Think of how much money your organization spends
  on error correction each year.
• Implementing a Design Control system can cut long
  term costs as well as improve quality and
  eliminate waste.

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Technology In Design

• In todays changing world, technologies like
  Computer Aided Design (CAD) have emerged as the
  standard tool in designing new products.

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Brief Overview of CAD

• Can be used to simulate real-world situations.
• Multi-User CAD systems
• Design Review
• Computer Aided Inspection (CAI)
• Computer Aided Testing (CAT)

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Why Implement a CAD System?

• Reduce costs
• Improve Accuracy of Design
• Improve Accuracy of Testing
• Overall Improvement in Quality

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The Taguchi Method

• The Taguchi Method for quality improvement is
  named after Dr. Genichi Taguchi who first
  introduced the method at ATT Bell Laboratories
  in 1980.

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The Taguchi Method

• The Taguchi Definition of Quality
• differs from traditional definitions of quality
• Taguchi said Ideal Quality is delivered when a
  product or service performs its intended function
  throughout its projected life under reasonable
  operating conditions without harmful side
  effects.

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The Taguchi Method

• Robust Design
• products should be designed so that they are
  free of all defects and are of the highest
  quality.

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Robust Design(The Taguchi Method)

• Three Step Method for Creating Robust Designs
• Concept Design
• Parameter Design
• Tolerance Design

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Concept Design

• Deals with the design of the process.
• Properly selecting process components and methods
  can reduce costs and increase the quality of the
  finished product.

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Parameter Design

• Deals with finding the optimal levels of
  variables that management can control in a
  process.
• Parameter design does not usually affect
  production costs, but rather attempts to find the
  best level of performance for the system.

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Tolerance Design

• Refers to finding the acceptable variation limits
  after the parameter design has been established.
• Usually results in an increase in production
  costs, but also an increase in production quality.

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Robust Design Steps

• In order to create a robust design, the following
  steps are used to incorporate the three
  perspectives Taguchi states.

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Steps for Creating a Robust Design
1. Identify the main Function 2. Identify the noise factors and testing conditions 3. Identify the quality characteristics to be observed and the objective function to be optimized 4. Identify the control factors and their alternative levels
5. Design the matrix experiment and define the data analysis procedure 6. Conduct the matrix experiment 7. Analyze the data and determine near optimum levels for the control factors 8. Predict the performance at these levels
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Benchmarking

• Another method that can be helpful in creating
  high quality designs is benchmarking.
• A benchmark is a company which is recognized for
  being the best in a certain field.

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Benchmarking

• Companies model themselves after the benchmark
  corporations in their specific field.
• The initiator firm might contact the target firm
  for information and statistics to be used for
  improvement of both corporations.

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Benchmarking

• There are six types of benchmarking.
• Process Benchmarking
• Financial Benchmarking
• Performance Benchmarking
• Product Benchmarking
• Strategic Benchmarking
• Functional Benchmarking

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QS 9000

• QS9000 is a supplier development program
• Provides a supplier standard for auto companies
• QS9000 has a requirement dealing with design
  control

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QS 9000

• The Design Control Requirement of QS9000.
• Suppliers must be qualified in value engineering,
  geometric tolerance and dimensioning, and the
  Taguchi Method.

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QS9000 A Real World Example

• A team of representatives from GM, Ford and
  Chrysler developed the QS9000 standard, including
  the standard for design control.
• Suppliers to these auto manufactures need to be
  QS9000 certified.

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Exercise

• Write down the approximate annual cost of error
  correction and losses due to poor quality in your
  organization.
• Now calculate approximately how much a design
  control system such as CAD would cost to
  implement. A QMS/ISO9000 Design control system
  can cost between 10,000 and 500,000, depending
  on the size of the corporation.
• Consider that it could be free to employ the
  Taguchi Method and also improve quality and cut
  costs.

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Summary

• Design Controls can help improve quality and cut
  costs.
• Free ideas like the Taguchi Method are harder to
  implement but can pay off in the end.
• Technology like CAD systems can also aid in
  design quality

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Bibliography

• http//mijuno.larc.nasa.gov/pap/robdes/robdes.html
  DESIGN FOR COST AND QUALITY THE ROBUST DESIGN
  APPROACH. By Resit Unal and Edwin B. Dean
• Managing Quality, An Integrative Approach By S.
  Thomas Foster
• Plant and Service Tours in Operations
  Management by Roger W. Schmenner
• http//manufacturing.software-directory.com/softwa
  re-2.cdprod1/014/863.QMS.Programs..ISO.9000.Design
  .Control.ISO.9000.44.shtml QMS PROGRAMS /ISO 9000
  DESIGN CONTROL (ISO 9000/4.4)