Impacting Design Quality through Key Parameter Development...

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  • Impacting Design Quality through Key Parameter Development &

    Management

    Using KPD&M during Technology & Product Development Processes to Prevent Design Problems

  • The DigiMaster 9100 digital printing system

    Over 10,000 parts< 30 major subsystems (chemo-opto-mechatronics)

    Reqd 6 image quality across 15 measurable attributesReqd 150K MIBSC within 95% Confidence Limits

  • How do we impact Design Quality

    2 main ways.

    Pro-actively during technology development & product design processes

    Reactively after we discover a problem in production & use environmentuse environment

    Our focus will be on Problem Prevention in the early development of Key Parameters!

    Intro to KPD&M, Copyright 2010, PDSS Inc. 3

  • 7 Key measures for credibility

    Measurability

    Stability

    Adjustability

    Interactivity

    Sensitivity / Significance

    Capability

    RobustnessIntro to KPD&M, Copyright 2010, PDSS Inc. 4

  • Preventing Problems Early in the Development Processes

    The US Armys Armament Research, Development & Engineering Center (ARDEC)has created a new Technology & Product development Process called Vector

    Vector has Key Parameter Development Tasks & Best Practices heavily integrated into its PhasesPractices heavily integrated into its Phases

    Intro to KPD&M, Copyright 2010, PDSS Inc. 5

    TD Phase1:Technology Planning &

    Requirements

    TD Phase 2:Technology

    Concept Development

    TD Phase 3: Technology

    Development & Initial

    Optimization

    TD Phase 4: Technology

    Integration & Final

    Optimization

    EMD Phase1:Product Planning & Requirements

    EMD Phase2:Product &

    Process Concept Development

    EMD Phase 3: Subsystem

    Design & Initial Optimization

    EMD Phase 4: System

    Integration & Final Optimization

    EMD Phase 5: Product

    Verification & Process

    Validation

    Vector Technology Development Process

    Vector Product Development Process

  • Example of Vector Technology Development Process Swim lanes loaded with major KPD&M Tasks

    Vector Swimlanes with KPD&M Process & Enabling DFLSS TMBPs by TD Phase

    Swimlanes Systems

    Engineering

    Gather &

    Define KEY

    (NUD)

    Customer

    Needs

    Translate,

    rank &

    prioritize

    KEY (NUD)

    System

    Level

    Technical

    Reqts

    Define Key

    System

    Level

    Functional

    Responses

    (Ys)

    Define

    System KFR

    Target

    Values &

    Tolerances

    Develop &

    Load KPM

    data base

    Develop

    Capable

    System Level

    Measurement

    Systems

    ID

    candidate

    System

    Level KAPs

    & KFRPs

    ID System

    Level

    Noise

    Maps

    Define KP

    System Flow-

    down Tree

    Design

    System Level

    KP

    Development

    DOEs &

    Verification

    Test Plans

    Conduct

    System Level

    Nominal

    Performance

    experiments

    Conduct

    System Level

    Robustness

    Performance

    experiments

    Conduct

    System Level

    Performance

    Balancing

    experiments

    Document

    System Level

    KPM Data

    base

    Transfer KP

    Data base

    to

    Production

    & Supply

    Chain

    Design Engineering Gather &

    Define KEY

    (NUD)

    Customer

    Needs

    Translate,

    & allocate

    KEY (NUD)

    Sub Level

    Technical

    Reqts

    Define Key

    Sub Level

    Functional

    Responses

    (Ys)

    Define Sub

    Level KFR

    Target

    Values &

    Tolerances

    Develop

    Capable Sub

    Level

    Measurement

    Systems

    ID candidate

    Sub Level KAPs

    & KFRPs

    ID Sub

    Level

    Noise

    Diagrams

    Define Sub

    Level KP

    Flow-

    down

    Trees

    Design Sub

    Level KP

    Development

    DOEs &

    Verification

    Test Plans

    Conduct Sub

    Level

    Screening

    experiments

    Conduct Sub

    Level

    Modeling

    experiments

    Conduct Sub

    Level

    Robustness

    experiments

    Conduct Sub

    Level

    Tolerance

    Balancing

    experiments

    Document

    Sub Level

    KPM Data

    base

    Quality Engineering Develop Define &

    TD Phase 1 TD Phase 2 TD Phase 3 TD Phase 4

    Intro to KPD&M, Copyright 2010, PDSS Inc. 6

    Quality Engineering

    & Systems

    Assurance

    Develop

    Capable

    System & Sub

    Level

    Measurement

    Systems

    Define &

    Conduct

    System &

    Sub Level KP

    Verification

    Tests

    Logistics Gather &

    Define KEY

    (NUD)

    Customer

    LOG Needs

    Translate,

    & allocate

    KEY (NUD)

    Sub Level

    Technical

    LOG Reqts

    Define Key

    Sub Level

    Functional

    Responses

    (Ys)

    Define Sub

    Level KFR

    Target

    Values &

    Tolerances

    Develop

    Capable Sub

    Level

    Measurement

    Systems

    ID Candidate

    Sub Level KAPs

    & KFRPs

    ID Sub

    Level

    Noise

    Diagrams

    Define Sub

    Level KP

    Flow-

    down

    Trees

    Design Sub

    Level DOEs &

    Verification

    Test Plans

    Conduct Sub

    Level

    Screening

    experiments

    Conduct Sub

    Level

    Modeling

    experiments

    Conduct Sub

    Level

    Robustness

    experiments

    Conduct Sub

    Level

    Tolerance

    Balancing

    experiments

    Document

    Sub Level

    KPM Data

    base

    Project

    Management

    Assure all

    KPD&M

    tasks are

    properly

    selected,

    resourced &

    realistically

    scheduled

    Process Assurance Assure the

    KPD&M

    Process is up

    to date &

    documented

    in the PAL

  • Reacting to a Cost or Quality Problem after the Product is in Production & Use

    Key Parameters & the Key Parameter Data base were not identified during the development processes.

    We must do that developmental work now, even though we are past launch & in production!

    We can follow an 11 Step KP Development Process to get that work done better late than never!

    now that we know that KPM is essential to meet our cost goals & efficiently manage design & process quality

    Can be done as a special KP project during production.

    Intro to KPD&M, Copyright 2010, PDSS Inc. 7

    KPD Step 1

    KPD Step 2

    KPD Step 3

    KPD Step 4

    KPD Step 5

    KPD Step 6

    KPD Step 7

    KPD Step8

    KPD Step 9

    KPD Step 10

    KPD Step 11

    KPD Step 12

  • 11 General Steps in KPD after you are in Production if you did NOT do KPD during Technology or Product Development

    Project Planning & Mgt., Monte Carlo Sim., Cost Estimation, SMART reqts. & goal ID, Intro to KPD&M Module

    Step 1: Create a KPD&M Project Charter

    Specific, in-depth experience; Technical expertise & judgment, DFLSS training, JIT training & mentoring in KP tool sets

    Step 2: Create a cross-functional team of experts to help ID a thorough set of KPs

    Customer/Stakeholder ID, Interviewing Methods, KJ Analysis, NUD vs. ECO classification, Kano Analysis, QFD & HOQs, Doors, Relational data base

    Step 3: Generate / Assess requirement clarity, classification & flow-down

    I-O-C Diagramming, P-Diagmg, Noise Diagmg, System Noise Mapping, Boundary & Interface Diagmg, 1st Principles Modeling & Simulation

    Step 4: Generate I-O-C-Diagrams, P-Diagrams, Noise & Boundary Diagrams

    Functional Diagmg, Flow Diagmg, Cockpit SW, KP Data base dev., KP Step 5: Structure a Key Parameter Flow-

    KPD&M Process Step Enabling Tools & Methods

    Functional Diagmg, Flow Diagmg, Cockpit SW, KP Data base dev., KP Scorecards, KP Reqts. & Measured Y worksheets

    Step 5: Structure a Key Parameter Flow-down Tree & Relational Data base

    NUD vs. ECO classification, Kano Analysis, Pareto process, QFD ranking, Function Trees & Flow Diagmg., Noise Diagmg, FMEAs

    Step 6: ID unique sub-areas of focus; lean out, rank & prioritize the areas to work on

    Measurement Systems Analysis, Gage R&R StudiesStep 7: Prove measurement systems are capable

    Hypothesis formation, SPC & Cp/Cpk studies, DOEs, t-Tests, ALT, HALT, HAST, Duane Plotting

    Step 8: Design & conduct experiments on candidate Key Parameters & Noises

    ANOVA, Descriptive & Inferential Statistical methods, Regression Analysis, Correlation Analysis, Confidence Intervals, Main effects & interaction plotting

    Step 9: Analyze data using ANOVA & other statistical methods to ID sensitivities & Cpk

    Screening DOEs, ANOVA, Taguchis Loss Function, Additive Variance Modeling, SPC & Cp/Cpk Studies, F Ratios

    Step 10: Establish & verify tolerance ranges & % contribution to variation of Key Ys

    Control Planning, SPC & Cp/Cpk Studies, KP documentation, KP relational data base & Score cards

    Step 11: Create a Mfg. & Production implementation & control plan for KPs