Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why...

KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org

BetaPrototypeandTestPlanModule4AKeyQues(ons

KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org

o Manyhardwareinnovatorsexcelatcrea(ngtechnically-viablealphaprototypes,butlosecustomerandinvestorconfidencebyintroducingseveralfailedversionsofbetaprototypesbeforecommercializingtheirproduct

o Abasicunderstandingofhowtoreducethenumberofvaria(onsofbetaprototypessaveshardwareinnovatorsvaluable(meandmoney

2

Whyisthismoduleimportant?Mo1va1on


BetaPrototypeAndTestPlanWheredoesthisfitintothedevelopmentcycle?

ConceptandFeasibility Defini1on Productand

ProcessDesignImplementandValidate

Produc1onandStock

LaunchandClosure

Pre-alpha Alpha Beta Pilot Ramp Scale

PHAS

ES

BUILDS

EngineeringValida9on

DesignValida,on

ProcessValida,on

ConceptValida9on

3

PRODUCTDESIGNOBJECTIVESMarketResearch

DesignResearchFeasibility

DevelopmentQualifica1on

FieldReadinessLaunch

ManufacturingCapacity

MANUFACTURINGREADINESSLEVELSLevels: 109987654321

MfgDevelopmentManufacturingResearch

MfgCapability

Produc(on


(MRLs)ManufacturingReadinessLevels

MaterialSolu1onsAnalysis TechnologyDevelopment EngineeringandManufacturingDevelopment

Produc1onandDeployment

Opera1onsandSupport

BasicmanufacturingImplica(onsIden(fied

ManufacturingConceptsIden(fied

ManufacturingProofofConceptdeveloped

Capabilitytoproducethe

technologyinalaboratoryenvironment

Capabilitytoproduceaprototypecomponents

inaproduc1onrelevant

environment

Capabilitytoproduceaprototypesystemor

subsysteminaproduc1on-relevant

environment

Capabilitytoproducesystems,

subsystemsorcomponents

inaproduc1on-relevant

environment

Pilotlinecapability

demonstrated.Readytobegin

low-rateproduc(on

LowRateProduc(on

demonstrated.Capabilityinplacetobegin

FullRateProduc(on

FullRateProduc(on

demonstratedandleanproduc(onprac(cesin

place

1 2 3 4 5 6 7 8 9 10

Thismodule’scontentisrelevantattheseMRLs

Pre-alpha Alphaprototypes Beta

prototypes Pilotprototypes

4


o Learningobjec(veso Differencebetweenalphaandbetaprototypeso Designforfailuremodeandeffectsanalysis(DFMEA)— Whatitisandhowtouseittoyourbenefit

o Manufacturingresources

5

ModuleOutline


o LO1.Whatarethekeyques(onstoconsiderwhendesigningandtes(ngabetaprototype?

6

LearningObjec1ves


o Whatistheexpecta(onofthecustomer,industry,ormarketformyproduct?

o WhatamIdesigningmyproductfor(e.g.,durability,serviceability)?

o Whatarethemostcommonmistakestoavoid?o HowdoIavoidthedevelopmentofseveralprototypemodifica(ons?

o WheredoIgoforprototypingservices?o Whoarethemanufacturingexpertsthatcanhelpmethroughthisprocess?

7

KeyQues9onsWhatThisModuleAddresses


o Developingaproductwithoutconsideringhowtodesignforitsopera(ngenvironment

o Launchingaproductwithoutdesigningforpoten(alfailuremodes

o Focusingonlowcostandspeedtomarketovercarefuldesignqualitymanagementanddesignformanufacturing

o Over-designingtheproductandfailingtoachievemarginspredicted

o Fallingintothetrapofredesigningaproductmul(ple(mes,whichaddstoproductdevelopmentcoststhatexhaustcompanyfundinganddelaysproductintroduc(ontomarket

Tobesuccessfulyourproductmustbeunique,butyourmanufacturingprocessshouldnotbe!

8

Commonmistakesandmisconcep9onsBetaPrototypeAndTestPlan


Therearetwotypesofalphahardwareprototypes:o A“looks-likeprototype”thatprovidesinsighttoergonomicsandaesthe(cs

o A“works-likeprototype”thatdemonstrateskeyfunc(onalelements

o Alphahardwareprototypesareodenconsideredtobe“labexperiments”thatarenotnecessarilydesignedforthecommercialrequirements/environments

o Theydemonstratewhattheproductiscapableofdoing

9

BasicsAlphaHardwarePrototype


o Alphahardwareprototypesusekeyfeaturesofthehardwareproducttoallowpeopletointeractwithitsfunc(onalityandproposedsolu(on

o Theyareusedtoprovethatcorefeaturesoftheproductworkinadevelopmentortes(ngenvironmentunderidealcondi(ons

10

Basics(cont.)AlphaHardwarePrototype


o Betahardwareprototypesareamorepolishedversionofthekeyfeaturesofthehardwareproduct;theycanbeuseddirectlybyacustomer

o Theyarebuiltwiththeintenttoprovethatpeoplewantthesolu(onbydemonstra(ngitinthecommercialrequirements/environments— Theyareusedtoprovethatcorefeaturesworkforasmallsetofcoopera(ngbetacustomersunderless-than-idealcondi(ons

11

BasicsBetaHardwarePrototype


o Betahardwareprototypesareusedtoelicitcustomerfeedbackandgatheraddi(onaldatarela(ngtousageandfeaturesneededtobeabletosupporttweakingtheproductbeforeproductlaunch— Theycanberunprivatelyorthroughahandpickedsetofcustomersand/orstrategicpartners

o Theydemonstratethefinishedproduct,exceptforanyimportantcustomerrequirementsthathavenotyetbeendiscovered

12

Basics(cont.)BetaHardwarePrototype


o Companydescrip1on:Thehybridrivetweldtechnologycombinestheadvantagesofself-piercerive(ngwithresistancespotweldinginjoiningofdissimilarmaterials(aluminumtosteel)

o Companytype:— Product— Material— ManufacturingProcess— ManufacturingService— ManufacturingOpera(ons

13

Casestudy1-RivetweldjoiningAlphatoBetaPrototype

sheet-to-cast

composites

sheettotube

cross-section

tube

highstrengthsteel

Source:Op9malProcessTechnologies

✔


Casestudy1-Rivetweldjoining(cont.)

TechnologyReadinessLevel

14

Basicprinciplesobservedandreported

Technologyconceptand/orapplica(onformulated

Proofofconcept

analyzedandexperimented

on

Componentorsystem

valida(oninlab

environment

Systemvalida(on,tes(nginopera(ng

environment

Prototype/pilotsystemverifica(oninopera(ng

environment

Fullscaleprototypeverifiedinopera(ng

environment

Actualsystemcompleteandfunc(oninginopera(ng

environment

Actualsystemtestedanddatacollectedoverlife(meofsystem

1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year1progress




15



Proofofconcept


on

Componentorsystem

valida(oninlab

environment


environment


environment


environment


environment


1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year1progress

Year2progress



o Whenatestfailsatareadinesslevel,thereisaneedtoretreatbackwards(odenbacktwolevels)

Example:IfthefullscaleprototypefailstobeVerifiedinOpera(ngEnvironment(MRL7),youhavetogobacktoMRL5totestopera(ngenvironments


16



Proofofconcept


on

Componentorsystem

valida(oninlab

environment


environment


environment


environment


environment


1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year3Retreat

Year1progress

Year2progress

Ififfails….


Casestudy1-Rivetweldjoining(cont.)ManufacturingReadinessLevels

MaterialSolu1onsAnalysis TechnologyDevelopment EngineeringandManufacturingDevelopment

Produc1onandDeployment

Opera1onsandSupport

BasicmanufacturingImplica(onsIden(fied

ManufacturingConceptsIden(fied

ManufacturingProofofConceptdeveloped

Capabilitytoproducethe

technologyinalaboratoryenvironment

Capabilitytoproduceaprototype

componentsinaproduc(onrelevant

environment

Capabilitytoproducea

prototypesystemorsubsystemina

produc(on-relevant

environment

Capabilitytoproducesystems,

subsystemsorcomponentsinaproduc(on-relevant

environment

Pilotlinecapabilitydemonstrated;readytobegin

low-rateproduc(on

LowRateProduc(on

demonstrated;capabilityinplacetobeginFullRate

Produc(on

FullRateProduc(on

demonstratedandleanproduc(on

prac(cesinplace

1 2 3 4 5 6 7 8 9 10

17


ImaginethisprototypeiscurrentlyatmanufacturingreadinessMRL4andfacesthefollowingDFMorscaleupchallenges:q Some,butnotall,joiningsamplesmetcustomerqualityspecifica(ons

o Processnotrepeatableandnotprovenonavarietyofmaterialso Toomuchcustomizedtoolingo Poorunderstandingofcosttradeoffsofproposedprocessvs.exis(ngproduc(onprocesses

o Equipmentnotop(mizedformassproduc(on(automatedmaterialhandling,robo(cs)

o NoqualitycontrolmeasurementWhatac(onscanbetakentoaddressthechallengesabove?

18


AlphatoBetaPrototype



Ac1onsthatcanbetakentoaddresstheMRL4challengesonpriorslideinclude:o Designforquality:adoptedin-situweldassurancetes(ngtoensurequality

o Designforcustomerrequirements:includeddemonstra(onsonawidevarietyofmixedmaterials(Al,Mg,HSS)

o Designforcost:reducedcustomizedtoolingandalignedwithexis(ngproduc(onprocesses

o Designforreliability:usedFEA/CFDmodelingtoop(mizerivetshapeandjoiningprocess

o Designfortakt1me:includedautomatedrivetfeeder,integratedwithautoma(onequipment

19


AlphatoBetaPrototype



o Howwillthebetaprototypebeevaluatedbythecustomer?

o Whatfeatures/func(onsaremust-haves,nice-to-haves,orarenotthatimportanttothecustomer?

o Whatarethetypicalexpecta(onsforproductperformanceanddurability?

o Howmusttheproductoperate?o Howwilltheproduct’sperformanceandqualitybeevaluated?

o Whattes(ngisrequiredbeforemyproductwillbeconsideredforpurchasebythecustomer?

o CanIsimulateproductinopera(ontopredictperformancebeforeinves(nginphysicalprototype?

20

Whatdoesthecustomer,industry,ormarketexpectofmyproduct?

KeyQues1ons



o Designformanufacturability— CanIreduceBOM,materialtradeoffs,costreduc(ons?

o Designforassemblyandmanufacturingprocess— CanIreduceprocesssteps,labor?— CanIreducecapitalequipment,toolingcosts?— CanIreducescrap,improveyield?

o Designfordurability,designforopera(ngenvironment— HaveIconsiderednoise/vibra(on/harshnesstes(ng,loadingcondi(ons,engineerforlife(me?

21

WhatamIdesigningmyproductfor?KeyQues1ons


o Designformaintenanceserviceability— CanIdesigninservicecostreduc(ons?

o Designforpackaging— HaveIconsideredproductprotec(on,shippinglogis(cs,transporta(oncosts?

o Designforsustainability— CanIreducewastematerials,scrap,allowforrecyclability,usebiodegradablematerials?

o Designforcustomerusability— CanIdesigntomakeiteasytouseformycustomer?

22

WhatamIdesigningmyproductfor?(cont.)

KeyQues1ons


Lifecycle:o Howlongdoesmyproductneedtolast?o Whatdoesmyproductwarrantyneedtocover?o Whatistheexpecta(onofthecustomer?Customerusability:o Howwillmyproductbehandledbythecustomer?o Howwillitbeservicedifitrequiresmaintenanceandrepair?Logis1cs:o HowdoIneedtocareformyproductininventory?o Whatistheshelflifeofmyproduct?o Howwillmyproductbetransported?

23

Otherconsidera9onsKeyQues1ons


o Productprocesscostsarenotpredictableo Limitedpar(cipa(onorcoordina(onfromateamperspec(veo Launchismorereac(vethanproac(veo Takestoolongtolaunchtheproducto Notachievingthepredictedmarginso Overlookinglowestcostop(onsforproduc(onandassemblyo Toodependentonlowercostoverseaspartnersforqualitymanagement

o Over-promisingandunder-delivering

24

Commonmistakesandmisconcep9onsProductLaunch


o Productisengineeredwell,butcannotbeproducedo Productispoorlyengineeredbecauseadvancedsimula(ontoolswerenotused(FEA/CAE)

o Productisover-engineeredo Productmustbecompletelyredesignedo Failuretorethinkproductdesigntodriveoutcosto Productcostoverruns(i.e.,toolingandcapitolequipmentcosts)

25

Commonmistakesandmisconcep9onsProductDesign


o Processcannot“runatrate”asexpectedo Failuretoplanforeveryparto Poorpartqualityo Failuretoreduceopera(onscostsandwasteo Failuretoimprove,measure,ortrackqualityo FailuretoproperlymanageinventoryofinboundBOMoroutboundfinished-productstock

o Encounteringcapacityconstraintso Requiringmorespaceornewbuildingtoaccommodatenewsales

o Over-inves(nginopera(onsandrunningatlowcapacityrates26

Commonmistakesandmisconcep9ons

ProductProcess


Mistakesmade:o Introducedtheproductsixteenmonthslaterthanoriginal(meline

o Sole-sourcedsuppliersandranintopartsshortageswhensupplierscouldn’tdeliver

o Tookshortcutsonqualityinspec(onofbakerypackso Finalcostofvehiclewas$20,000/carmorethantheoriginaltargetprice

o Didnotdesignproductfordurabilityandexperiencedmul(plefailuresinthefield

27

Caststudy2–Start-upelectricvehiclecompanyDevelopingBetaPrototypes


Impact:o Companymarginswerenega(veonfirstvehiclelaunch

o Angeredpre-orderdepositcustomersbynotdeliveringvehiclebydateadver(sed

o Warrantycostskyrocketedwhenbakeriesfailedandside-impactcrashesledtolegalseklements

o Exhaustedinvestorfundsandfiledforbankruptcy

28

Caststudy2–Start-upelectricvehiclecompany(cont.)

DevelopingBetaPrototypes


Bestprac1ces:o Mi(gatedthecostriskbydevelopingadisciplinedapproachtocosttarge(ngfortheen(revehicleBOM

o Controlledproductop(onsandvaria(ons

o Mi(gatedsupply-chainrisksbysecuringmul(plesourcesofsuppliersforeachpart

o Mi(gatedqualityriskbyimplemen(ngDFMandcostupfrontwithinternalteamsandexternalsupplypartners

29

DevelopingBetaPrototypesCaststudy2– Start-upelectricvehiclecompany(cont.)


30

Bestimpact:o Companymarginswereposi(veonfirstvehiclelaunch

o Pre-orderdepositcustomershadtheirvehiclesdeliveredon(me

o Limitedfailuresexperiencedinthefield,whichcontrolledwarrantyandrecallcosts

o Receivedfollow-oninvestorfundstolaunchnewvehicleplamorms

Caststudy2–Start-upelectricvehiclecompany(cont.)



31

Casestudy3–LEDlampDevelopingBetaPrototypes

Whatistheexpecta1onofthecustomer,industry,ormarketformyproduct?o WorkingoffofB1-A,marketfeedbackwasconductedwithassistancefromindustrialdesignfirmpriortoprototypeitera(on,interviewingstakeholders(fieldcrews,distributors,u(lityexecu(ves).Theproductexpecta(onisanindustrialgradeLEDlamp,designedforuseinoutdoorstreetligh(ngcondi(ons.Thewarrantyrequirementsformunicipalcustomersodenare10years,meaningdurabilityandreliabilityarekeydecidingfactors.Therearealsominimumoutputandefficiencyrequirements,whicharequitehighgiventhestateofcurrentLEDtechnology.Thismeanstheproductmustusehighqualitycomponentswhilekeepingcostslow.

Product:B1-aandB1-b


WhatamIdesigningmyproductfor?(inorderofpriority)o Performance(lightqualitymeasuredinlumensdelivered)o Energyefficiency(measuredinlumenoutputperwakforthetotaldeliveredsystem)

o Reliability(reliabilitytoexceed10yearwarrantyrequirement)o PriceWhatarethecommonmistakestoavoid?o Spendingtoomuch(meintheweedstryingtominimizethecostofeverycomponentintheBOM.Iden(fythecorecomponentsthatdriveBOMandfocusonop(mizingthose.Forthiscasestudy,theLEDpackagingwasmostimportant. 32

Casestudy3–LEDlamp(cont.)


Product:B1-aandB1-b


HowdoIavoidthedevelopmentofseveralprototypemodifica1ons?o Makeextensiveuseofcomputersimula(onstovalidateheattransferperformanceofvariousdesignitera(onspriortogoingtophysicalprototype

o Implementdesignformanufacturingsoonerintheengineeringanddesignprocess.Thisiswheretheindustrialdesignfirmaddedalotofvalue,asinnovatorsareodenunabletoseethemanufacturingimplica(onlandminesearlyon(chassisdesignsthatwouldop(mizeforextrusionvs.stampingprocesses).

33



Product:B1-aandB1-b


o Theindustrialdesignfirmhadthein-housecapabili(estocreatemostofthecomponentpartsthatwereneededtomaketheproofofconceptprototype(3-Dprin(ng,CNCmachiningcapabili(es,etc.)

WheredoIgoforprototypingservices?o DFMconsul(ngfirms(suchasDragonInnova(on)o Industrialdesignfirmso Independentconsultants

34



Product:B1-aandB1-b


o HowdoIdesignnowtoavoidmistakesinthefuture?o HaveIconsideredallpoten(alfailuremodes?o Whatarethepoten(aleffectsofthosefailures?o Whatarethelikelycausesorreasonsforthosefailures?o Whatisthelikelihoodofoccurrenceandseverityofeachfailuremode?

Recommenda9on:Hardwarecompaniesandinnovatorsshouldins(tuteDesignforFailureModeandEffectsAnalysis*(DFMEA)asapartoftheirBetaPrototypePlans(seenextpage)

35

HowdoIavoidthedevelopmentofseveralprototypemodifica9ons?

KeyQues1ons

*Adaptedfrom“QualityTrainingPortal:19StepstoConductaDFMEA”www.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm


o Designforfailuremodeandeffectsanalysis(DFMEA)isahighlystructured,systema(cproduct-designmethodologyforpre-evalua(ngpoten(alproduct

o DFMEAisodenthefirststepofaproduct-orprocess-reliabilitystudy;itinvolvesreviewingasmanycomponents,assemblies,andsubsystemsaspossibletoiden(fyfailuremodes,andtheircausesandeffects

o Foreachcomponentorprocess,thefailuremodesandtheirresul(ngeffectsontherestofthesystemarerecordedinaspecificDFMEAworksheet

36

DesignforfailuremodeandeffectsanalysisFailureModeAndEffectsAnalysis


1.  Reviewthedesign:Useablueprintorschema(cofthedesign/producttoiden(fyeachcomponentandinterface

2.  Brainstormpoten(alfailuremodes:Reviewexis(ngdocumenta(onanddataforclues

3.  Listthepoten(aleffectsoffailure:Theremaybemorethanoneforeachfailure

4.  Assignseverityrankings:Basedontheseverityoftheconsequencesoffailure

5.  Assignoccurrencerankings:Basedonhowfrequentlythecauseofthefailureislikelytooccur

37

Step-by-stepConductADFMEA


6.  Assigndetec(onranking:Basedonthechancesthefailurewillbedetectedpriortothecustomerfindingit

7.  Calculatetheriskprioritynumber(RPN):SeverityxOccurrencexDetec(on

8.  Developtheac(onplan:Definewhowilldowhatbywhen9.  Takeac(on:Implementtheimprovementsiden(fiedbyyour

DFMEAteam10. Calculatetheresul(ngRPN:Re-evaluateeachofthepoten(al

failuresonceimprovementshavebeenmadeanddeterminetheirimpactontheRPNs

38

Step-by-step(cont.)ConductADFMEA


o Ensurethatallteammembersarefamiliarwiththeproductanditsdesign

o Iden(fyeachofthemaincomponentsofthedesignanddeterminethefunc(onorfunc(onsofthosecomponentsandinterfacesbetweenthem

o StudyallcomponentsdefinedinthescopeoftheDFMEAo Useaprintorschema(cforthereviewo Addreferencenumberstoeachcomponentandinterfaceo Tryoutaprototypeorsampleo Inviteasubjectmakerexperttoanswerques(onso Documentthefunc(on(s)ofeachcomponentandinterface

39

Step1-Reviewthedesign

ConductADFMEA


o Reviewdocumenta(onforcluesaboutpoten(alfailuremodesbeforeundertakingbrainstormingsessions

o Usecustomercomplaints,warrantyreports,andreportsthatiden(fythingsthathavegonewrong(i.e.,holdtagreports,scrap,damage,andrework)asinputs

o Considerwhatmayhappentotheproductunderdifficultusagecondi(onsandhowtheproductmightfailwhenitinteractswithotherproducts

40

Step2-Brainstormpoten9alfailuremodes

ConductADFMEA


o Considerpoten(alfailuremodesforeachcomponentandinterface

o Apoten(alfailuremoderepresentsanymannerinwhichtheproductcomponentcouldfailtoperformitsintendedfunc(onorfunc(ons

o Manycomponentswillhavemorethanonefailuremode.Donotleaveoutapoten(alfailuremodejustbecauseitdoesnothappenoden.Documenteachone.

Don’ttakeshortcutshere;thisisthe9metobethorough

41

Step2-Brainstormpoten9alfailuremodes(cont.)

ConductADFMEA


o Aneffectoffailureisdefinedastheimpactofafailureonasystemshoulditoccur

o Theeffectisrelateddirectlytotheabilityofthatspecificcomponenttoperformitsintendedfunc(on

o Somefailureswilleffectcustomers,otherseffecttheenvironment,theproduct-produc(onprocess,andtheproductitself

42

Step3– Listpoten9aleffectsoffailure

ConductADFMEA


o Theseverityrankingscaleiscri(caltothesuccessofDFMEAsbecauseitestablishesthebasisfordeterminingtheriskofonefailuremoderela(vetothatofanother— Severityrankingisbasedonarela(ve(notanabsolute)scalerangingfrom1–10(10meanstheeffecthasadangerouslyhighseverity,leadingtoahazardwithoutwarning;1meanstheseverityisextremelylow)

— ExampleformscanbefoundintheFMEAResourceCenter:hkp://www.qualitytrainingportal.com/resources/fmea/index.htm(ledcolumn,underFormsandCheckLists);FMEA’sseverityrankingscale:hkps://qualitytrainingportal.com/resources/fmea-resource-center/?sec(on=generic-severity-ra(ng-scale

o TheDFMEArankingscaleshouldbeusedconsistentlythroughoutanorganiza(on;thisenablescomparisonoftheRPNsofdifferentDFMEAStooneanother

43

Step4– Assignseverityrankings

ConductADFMEA


o Thebestwaytocustomizearankingscaleistostartwithagenericscaleandmodifyittobemoremeaningfultoyourorganiza(on

o Byaddingorganiza(on-specificexamplestotherankingdefini(ons,DFMEAteamswillhaveaneasier(meusingthescales;usingexamplessaves(meandimprovestheconsistencyofrankingsfromteamtoteam

o Asyouaddspecificexamples,consideraddingseveralcolumnswitheachcolumnfocusedonatopic.Onetopiccouldprovidedescrip(onsofseveritylevelsforcustomersa(sfac(onfailuresandanotherforenvironmental,health,andsafetyissues.Remember,though,thateachrowshouldreflectthesamerela(veimpactorseverityontheorganiza(onorcustomer.

44

Step4– Assignseverityrankings(cont.)

ConductADFMEA


o Thepoten(alcausemustbeknowninordertodeterminetheoccurrencerankingbecause,justastheseverityrankingisdrivenbytheeffect,theoccurrencerankingisafunc(onofthecause

o Theoccurrencerankingisbasedonthelikelihood,orfrequency,thatthecause(ormechanism)offailurewilloccur

o Ifthecauseisknown,itiseasiertoiden(fyhowfrequentlyaspecificmodeoffailurewilloccur

o Theoccurrencerankingscale,liketheseverityrankingscale,isarela(vescalerangingfrom1–10

45

Step5– Assignoccurrencerankings

ConductADFMEA


o Anoccurrencerankingof10meansthefailuremodeoccurrenceisveryhigh;ithappensallofthe(me(conversely,a1meanstheprobabilityofoccurrenceisremote)

o SeeFMEA’sFormsandChecklistswebpageforanoccurrencerankingscaleexample

o Yourorganiza(onmayneedtodevelopacustomizedoccurrencerankingscaletoapplytodifferentlevelsorcomplexi(esofdesign;itisdifficulttousethesamescaleforamodulardesign,acomplexdesign,andacustomdesign

o Someorganiza(onsdevelopthreedifferentoccurrencerankingscales((me-based,event-based,andpiece-based)andselecttheonethatappliestothedesignorproduct

46

Step5–Assignoccurrencerankings(cont.)

ConductADFMEA


o Toassigndetec(onrankings,considerthedesignorproduct-relatedcontrolsalreadyinplaceforeachfailuremodeandthenassignadetec(onrankingtoeachcontrol

o Thinkofthedetec(onrankingasanevalua(onoftheabilityofthedesigncontrolstopreventordetectthemechanismoffailure

47

Step6–Assigndetec9onrankingsConductADFMEA


o Detec(oncontrolsiden(fythecauseoffailure,themechanismoffailure,orthefailuremodeitselfaderthefailurehasoccurred,butbeforetheproductisreleasedfromthedesignstage— Adetec(onrankingof1meansthechanceofdetec(ngafailureisalmostcertain,whereasa10meansthedetec(onofafailureormechanismoffailureisabsolutelyuncertain

— ToprovideDFMEAteamswithmeaningfulexamplesofdesigncontrols,consideraddingexamples(edtothedetec(onrankingscalefordesign-relatedtopicssuchasdesignrules,designforassemblyanddesignformanufacturability(DFA/DFM)issues,andsimula(onandverifica(ontes(ng

— SeeFMEA’sFormsandChecklistswebpageforexamplesofcustomDFMEArankingscales

48

Step6–Assigndetec9onrankings(cont.)ConductADFMEA


o Preven(oncontrolsarealwayspreferabletodetec(oncontrols— Preven(oncontrolscomeindifferentformsandlevelsofeffec(veness

— Preven(oncontrolspreventthecauseormechanismoffailure(orthefailuremodeitself)fromoccurring;theygenerallyimpactthefrequencyofoccurrence

49

Step6–Assigndetec9onrankings(cont.)ConductADFMEA


o TheRPNprovidesarela(veriskranking;thehighertheRPN,thegreaterthepoten(alrisk— Sinceeachofthethreerela(verankingscalesrangesfrom1–10,theRPNwillalwaysbebetween1and1,000;theRPNisanexcellenttoolforpriori(zingfocusedimprovementefforts

o TheRPNiscalculatedbymul(plyingthethreerankingstogether:theseverityranking,theoccurrenceranking,andthedetec(onranking;calculatetheRPNforeachfailuremodeandeffectNote:ThecurrentAIAGFMEAManualsuggestsonlycalcula(ngtheRPNforthehighesteffectrankingforeachfailuremode.Wedonotagreewiththissugges(on.Webelievethatifthissugges(onisfollowed,itwillbetooeasytomisstheneedforfurtherimprovementonaspecificfailuremode.

50

Step7–Calculatetheriskprioritynumber(RPN)ConductADFMEA


o Takingac(onmeansreducingtheRPNo TheRPNcanbereducedbyloweringseverity,occurrence,ordetec(onindividuallyorincombina(onwithoneanother

o Areduc(onintheseverityrankingforaDFMEAisodenthemostdifficulttoakain—itusuallyrequiresadesignchange

o Reduc(onintheoccurrencerankingisaccomplishedbyremovingorcontrollingpoten(alcausesormechanismsoffailure

o Areduc(oninthedetec(onrankingisaccomplishedbyaddingorimprovingpreven(onordetec(oncontrols

o WhatisconsideredanacceptableRPN?Theanswerdependsontheorganiza(on.

Example:Anorganiza(onmaydecidethatanyRPNaboveamaximumtargetof200presentsanunacceptableriskandmustbereduced.Ifso,anac(onplan(whowilldowhat,bywhen)isneeded. 51

Step8–Developtheac9onplanConductADFMEA


DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on:o Designofexperiments(DOE)— Powerfulsta(s(calimprovementtechniquesthatcaniden(fythemostcri(calvariablesinadesignandtheop(malsewngsforthosevariables

o Mistake-proofing— Techniquesthatcanmakeitimpossibleforamistaketooccur,reducingtheoccurrencerankingto1

— Par(cularlyimportantwhentheseverityrankingis10

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Step8–Developtheac9onplan(cont.)ConductADFMEA


DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on(cont.):o Designforassemblyanddesignformanufacturability(DFA/DFM)— Techniquesthathelpsimplifyassemblyandmanufacturingbymodularizingproductsub-assemblies,reducingcomponents,andstandardizingcomponents

o Simula(ons— Simula(onapproachesincludepre-produc(onprototypes,computermodels,acceleratedlifetests,andvalue-engineeringanalyses

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Step8–Developtheac9onplan(cont.)ConductADFMEA


o Theac(onplanoutlinesthestepsneededtoimplementthesolu(on,includingwhowillperformthemandwhentheywillbecompleted

o Asimplesolu(ononlyrequiresasimpleac(onplan,whileacomplexsolu(onrequiresmorethoroughplanninganddocumenta(on;mostac(onplansiden(fiedduringaDFMEAwillfallunderthesimple“who,what,andwhen”category

o Responsibili(esandtargetcomple(ondatesforspecificac(onstobetakenareiden(fied

o Anac(onplanmaytriggeralarge-scaleproject.Ifthathappens,conven(onalprojectmanagementtools(includingPERTChartsandGankCharts)willberequiredtokeeptheac(onplanontrack.

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Step9–Takeac9onConductADFMEA


o Bycalcula(ngtheresul(ngRPN,thisstepinaDFMEAconfirmsthattheac(onplanhasproducedthedesiredresults

o TorecalculatetheRPN,reassesstheseverity,occurrence,anddetec(onrankingsforthefailuremodesadertheac(onplanhasbeencompleted

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Step10–Recalculatetheresul9ngRPNConductADFMEA


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Casestudy4– Automo9vebodystructuresDFMEA

o Joiningdissimilarmaterialsprocessestoproducelighterweightcars


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Exercise–DFMEAworksheetBetaPrototypeQualityPlan


o QualityTrainingPortal:10stepstoconductaDFMEAhkp://www.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm

o ChartItNow:DFMEAtemplatehkp://www.char(tnow.com/DFMEA-Template.html

o QIMacros:FMEAtemplateinExcelhkps://www.qimacros.com/lean-six-sigma-ar(cles/fmea-template/

o Systems2win:FMEAtemplatehkp://www.systems2win.com/solu(ons/FMEA.htm

o DMAICTools:PFMEA(defini(onsandexplana(ons)hkps://www.dmaictools.com/dmaic-analyze/pfmea

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DFMEA/PFMEAResources


o TechShop:Sharedmanufacturingspacehkp://www.techshop.ws/o Makerspace:Sharedmanufacturingspacehkp://makerspace.sp.edu.sg/

o QuickParts:3Dprin(ngservicehkp://www.3dsystems.com/quickparts

o R&DTechnologies:3Dprin(ngservicernd-tech.com

o Protolabs:3Dprin(ng,CNCmachining,injec(onmoldingservicewww.protolabs.com

o Make(me:CNCmachiningservicewww.make(me.io

o RapidManufacturing/Vaupell:Prototypesheetmetal,machinedparts,cablingservicehkps://rapidmanufacturing.com/

o CircuitHub:OndemandPCBmanufacturingservicehkps://circuithub.com/

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Sharedassetfacili9es/prototypingservicesManufacturingResources


Iden1fyregionalsuppliermatchmakingandconnec1onprograms.Examplesinclude:o GreentownLabsManufacturingIni(a(ve,aBoston-areaclean-technologyhardwareincubatorpartnershipwithMassachuseksManufacturingExtensionPartnership(MassMEP)hkp://www.greentownlabs.com/wp-content/uploads/2015/02/020515-Manufacturing-Ini(a(ve-PDF1.pdf

o InnoState,aMichiganentrepreneur-manufacturermatchmakingprogramorganizedbyMEPMichiganManufacturingTechnologyCenter(MMTC)hkp://innostatemi.com/

o PureMichiganBusinessConnect,amatchmakingportalwithlis(ngofeventshkp://www.michiganbusiness.org/grow/pure-michigan-business-connect/ 60

HowdoIfindmanufacturingexperts?ManufacturingResources


o Gettoknowyourlocalmanufacturingextensionpartnership(MEP)

o Secureamanufacturingexpertasanadvisor,evenifitmeansprovidingsomeequity

o Takeadvantageofre(redandsemi-re(redmanufacturingexpertswhoareodeneagertosharetheirexperienceandknowledgewithinnovatorsandstartups

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Recommenda9onsFindingManufacturingExper1se

Notsolici9nghelpfrommanufacturingexpertsisacommonmistake!


o SocietyofManufacturingEngineers(SME)ToolingU:Extensiveon-linemanufacturingtraininghkp://www.tooling.com/

o SMEManufacturingInsights®Videoshkp://www.sme.org/mi/

o SMEFundamentalManufacturingProcesses(FMP):44videosonmajormanufacturingprocesseshkp://www.sme.org/fmp/

o SMEDFMATraininghkp://www.toolingu.com/ilt/915101/Design-for-Manufacturability-and-Assembly-DFMDFA

o AdviceManufacturingProcesses:Shortvideosonarangeofcommonmanufacturingindustryprocesseshkp://www.advice-manufacturing.com/Manufacturing-Processes.html

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DFXTrainingResources

ManufacturingResources


o TheManufacturingIns(tute:Manufacturingskillscer(fica(onprogramshkp://www.themanufacturingins(tute.org/Skills-Cer(fica(on/Cer(fica(ons/NAM-Endorsed-Cer(fica(ons.aspx

o AMEAlliance:8-weekmanufacturingcer(fica(oncourseshkp://amealliance.org/8-week-cer(ficates

o AlisonIns(tute:Onlinemanufacturingtrainingclasseshkps://alison.com/learn/manufacturing

o DfRSolu(ons:Designformanufacturingtrainingprogramswww.dfrsolu(ons.com

o ElectronicsManufacturingTraininghkp://www.ipc.orgo ManufacturingSkillsTrainingProgramshkp://scien(fic-management.com/skills-training-programs

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DFXTrainingResources(cont.)



o Munro&Associates:Leandesignmanufacturingop(miza(ontraininghkp://leandesign.com/lean-design/

o Munro&Associates:Designprofitmanufacturingcos(ngsodwarehkp://www.designprofit.com/

o Ricardo:Productdevelopment,engineeringandmanufacturingtraining,andconsul(nghkp://www.ricardo.com/en-GB/What-we-do/knowledge/Training/

o SocietyofAutomo(veEngineers(SAE):DFM,DFAtraininghkp://training.sae.org/seminars/92047/

o Tec-Ease,Inc.:DesignforassemblyandGD&Ttraininghkp://www.tec-ease.com/design-assembly.php

o EngineersEdge:DFMAtraininghkp://engineersedge.com/training_engineering/design-for-manufacturing-training.htm

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DFXTrainingResources(cont.)ManufacturingResources


o OMNEX:DFMAtraininghkp://www.omnex.com/training/rd_Series/design_manufacturing_assembly.aspx

o SSA:DFMAtraininghkp://www.ssa-solu(ons.com/training-program/design-for-manufacturing-assembly.php

o ManufacturingQualityTrainingASQwww.asq.orgo Automo(veIndustryAc(onGroup’s(AIAG’s)AdvancedProductQualityPlanning(APQP)(availableviacoursesoron-line)hkp://www.aiag.org/store/training/details?CourseCode=ELCTO

o TUDeld/UNEP:Designforsustainabilityhkp://www.d4s-sbs.org/o SurfaceMountTechnologyAssocia(on(SMTA):Onlinemanufacturingtrainingcourseswww.smta.org

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o SixSigmaU:Designforsixsigmatraininghkp://www.6sigma.us/design-for-six-sigma-dfss.php

o NPDSolu(ons:Designformaintenanceandserviceabilityworkshopshkp://www.npd-solu(ons.com/featuredworkshops/dfsws

o DragonInnova(ons:BOMdevelopmenttoolshkps://www.dragoninnova(on.com/dragon-standard-bom

o GreentownLabsandMassMEP:Bestprac(cesfortrainingstartupstoworkwithmanufacturershkp://greentownlabs.com

o Invent@NMU:Hardwareentrepreneuracceleratorprogramfocusedonaccelera(ontomarketthroughDFXprincipalshkp://www.nmu.edu/invent/home

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o Connec(ngGreenTechnologyEntrepreneurs:Buildingconnec(onsforgreentechnologyentrepreneurshkps://www.infodev.org/infodev-files/connec(ng-green-technology-entrepreneurs-full.pdf

o E2byShoptech:All-in-onemanufacturingsodware(quo(ng,accoun(ng,produc(on,inventory,etc.)www.shoptech.com

o BasicCADtools:Autodesk’sFusion360hkp://www.autodesk.com/products/fusion-360

o BasicCADtools:SolidWorkswww.solidworks.com

o GeometricGlobal:Designformanufacturingsodwarehkp://info.geometricglobal.com/design-for-manufacturing-sodware

o Design-IV:DFM/DFAsodwarehkp://www.design-iv.com/

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DFXTrainingResources(cont.)



ManufacturingTrainingNetworkResourceso U.S.DepartmentofEnergy’sOfficeofEnergyEfficiencyandRenewableEnergy(EERE)hkp://energy.gov/eere/office-energy-efficiency-renewable-energy

o U.S.DepartmentofEnergy’sAdvancedManufacturingOffice(AMO)hkp://energy.gov/eere/amo/advanced-manufacturing-office

o Na(onalNetworkofManufacturingIns(tutes(NNMIs)hkp://manufacturing.gov/nnmi/ins(tutes.html

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OtherManufacturingResources


Wheretolookforaddi1onalresourcesonline:o UniversityandU.S.na(onallaboratorymanufacturingwebsitesandtrainingprograms

o Exis(ngdesignformanufacturabilitytrainingresources(e.g.,SME)

o ManufacturingExtensionPartnerships(MEPs)programshkp://www.nist.gov/mep/

o Hardware-basedincubatorsandacceleratorso Entrepreneurialmentorshipandexpert-in-residence(EiR)programs

o Entrepreneurialcontractmanufacturingmatchmakingprograms

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Other(cont.)ManufacturingResources


o DragonInnova(onBlog,September8,2016:Top10ManufacturingReasonsHardwareCompaniesFailhkp://blog.dragoninnova(on.com/2016/09/08/1414/

o MForesightReportManufacturing101:AnEduca(onandTrainingCurriculumforHardwareEntrepreneurs(downloadablePDFfile)hkp://mforesight.org/download/5107/

o MMTCProduc(onPrepara(onProcess(3P)hkps://www.the-center.org/Our-Services/Opera(onal-Excellence/Lean/Produc(on-Prepara(on-Process-(3P)

o Wikipedia:Failuremodeandeffectsanalysishkps://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis

o QualityTrainingPortal:19stepstoconductaDFMEAwww.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm

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References

Glossary

Module 4A

Development is the systematic use of scientific and technical knowledge to meet specific

objectives or requirements.

Qualification is either the process of qualifying for an achievement, or a credential attesting to

that achievement.

Field Readiness is the stage of development just prior to final launch. It is time to review the Pilot run and determine if there are any “game stopper” issues.

Prototype is an early sample, model, or release of a product built to test a concept or process or to act as a thing to be replicated or learned from

Manufacturing Rediness Level (MRL) is a measure developed by the United States Department of Defense (DOD) to assess the maturity of manufacturing readiness

http://www.businessdictionary.com/definition/development.html

https://en.wikipedia.org/wiki/Qualification

http://www.npd-solutions.com/launch.html

https://en.wikipedia.org/wiki/Prototype

https://en.wikipedia.org/wiki/Manufacturing_readiness_level

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