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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)

Req’d 6σ image quality across 15 measurable attributesReq’d 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 Army’s 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 Est imation, 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 A nalysis, NUD vs. ECO classification, Kano Analysis, QFD & HOQs, Doors, R elational data base

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

� I-O-C Diagramming, P-Diagm’g, Noise Diagm’g, System Noise Mapping, Boundary & Interface Diagm’g, 1 st Principles Modeling & Simulation

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

� Functional Diagm’g, Flow Diagm’g, Cockpit SW, KP Da ta base dev., KP Step 5: Structure a Key Parameter Flow -

KPD&M Process Step Enabling Tools & Methods

� Functional Diagm’g, Flow Diagm’g, Cockpit SW, KP Da ta 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 p rocess, QFD ranking, Function Trees & Flow Diagm’g., Noise Diagm’g, FMEA s

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 method s, Regression Analysis, Correlation Analysis, Confidence Intervals, Main e ffects & interaction plotting

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

� Screening DOEs, ANOVA, Taguchi’s Loss Function, Add itive 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 document ation, KP relational data base & Score cards

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

2 Ways to enable Design Quality… Vector Swimlanes with KPD&M Process & Enabling DFLSS TMBPs by TD Phase

Swimlanes Systems

Engineering

Gather &

Defi ne 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 &

Defi ne 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

& Systems

Assurance

Develop

Capable

System & Sub

Level

Measurement

Systems

Define &

Conduct

System &

Sub Level KP

Verifi cation

Tests

Logistics Gather &

Defi ne 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 &

real istically

scheduled

Process Assurance Assure the

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

Apply Key Parameter Development pro-actively to prevent problems….

Intro to KPD&M, Copyright 2010, PDSS Inc. 9

Process Assurance Assure the

KPD&M

Process is up

to date &

documented

in the PAL

� Project Planning & Mgt., Monte Carlo Sim., Cost Est imation, 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 A nalysis, NUD vs. ECO classification, Kano Analysis, QFD & HOQs, Doors, R elational data base

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

� I-O-C Diagramming, P-Diagm’g, Noise Diagm’g, System Noise Mapping, Boundary & Interface Diagm’g, 1 st Principles Modeling & Simulation

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

� Functional Diagm’g, Flow Diagm’g, Cockpit SW, KP Da ta 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 p rocess, QFD ranking, Function Trees & Flow Diagm’g., Noise Diagm’g, FMEA s

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 method s, Regression Analysis, Correlation Analysis, Confidence Intervals, Main e ffects & interaction plotting

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

� Screening DOEs, ANOVA, Taguchi’s Loss Function, Add itive 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 document ation, KP relational data base & Score cards

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

KPD&M Process Step Enabling Tools & Methods

Apply Key Parameter Development reactively to correct existing problems…. & prevent them in the future.