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.
Top Related