Integration Quality Function Deployment Method (QFD) and Lean Manufacturing

ARIEF RAHMAWANM10158036

Business Administration DepartmentCollege of Management

National Pingtung University of Science and Technology

Taiwan2012

Many manufacturer cannot reach optimum production capabilities

Lean is a management philosophy focused on identifying and eliminating waste throughout a product’s entire value stream, extending not only within the organization but also along the company’s supply chain network

Manufacturer propose to obtain continous improvement

Introduction

Wastedefect

Unnecessary transport and

handling

Unnecessary motion

inventoriesOverproduction

Over-processing

waiting

Goals

QFD

Translate these needs into technical characteristics and specifications

Create quality of product focusing on customer need

Prioritize spoken and unspoken customer wants and needs

Research GAP

Lean only focus in eliminating waste entire the value stream

Quality Function Deployment only focus on customer requirement

Is Structured method used in the process of planning and product development to establish specification needs and desires of consumers, and to evaluate systematically Capabilitas a product or service to meet the needs and desires of consumers (Lou Cohen, 1995)

Quality Function Deployment

Benefit of QFD

Focusing designing new products and services to customer requirements

Able to translate Quality characteristics to be technical specifications

Prioritize design activities. This ensures that the design process is focused on the needs of the customer hierarchy

Able to perform benchmarking

Analyzing the performance of the company's products to the performance of competitors, major company to meet the needs of key customers

Able to clearly define the design direction early in the design process

Focus on design, this will reduce the length of time required for the overall design cycle, reducing time to market for new productsAble to translate input into subtitute quality characteristics

Quality Function Deployment Phases

IDENTIFYING VOICE OF CUSTOMER

CONSTRUCT THE HOUSE OF QUALITY

Product plannin

g

Product design

Process plannin

g

Process control

has a matrix format to capture a number of issues that are vital in the QFD approach.

Translates customer requirements into engineering characteristics to be met by a new product design

Helps how an organization will meet those requirements

House of Quality Matrix

Submatrix in HoQ

Customer requirements (HOWs)

• a structured list of requirements derived from customer statements

Technical requirements (WHATs)

• a structured set of relevant and measurable product characteristics

Planning matrix• illustrates customer perceptions observed in market

surveys. Includes relative importance of customer requirements, company and competitor performance in meeting these requirements

Interrelationship matrix

• illustrates the QFD team's perceptions of interrelationships between technical and customer requirements. Filling this portion of the matrix involves discussions and consensus building within the team and can be time consuming.

Technical correlation (Roof) matrix

• used to identify where technical requirements support or impede each other in the product design. Can highlight innovation opportunities

Technical priorities, benchmarks and targets

• The final output of the matrix is a set of target values for each technical requirement to be met by the new design, which are linked back to the demands of the customer

Relationships Symbol Values

Strong ● 9

Moderate ○ 3

Weak ▽ 1

None 0

Symbol of Relationship in HoQ

Simbol Keterangan

+ Possitive correlation between two technical responses

- Negative correlation between two technical responses

<blank>There is no relationship between the two technical responses

Symbol of Technical Correlation in HoQ

The literature reviewed revealed the following “knowledge” about lean : lean thinking has evolved from the manufacturing environment to be applicable

throughout an organisation and in industries outside manufacturing the term “lean” and its association with “Japanese management” techniques has caused

confusion and difficulty when addressing the topic outside of the manufacturing context interest in research and implementation of lean continues to increase and heavily

influenced by Toyota Motor Company employing lean principles have dominated the “how-to-do” lean literature the majority of research has historically been from engineering and operations

management disciplines with a recent increase of interest from disciplines associated with human resource and organisational development

lean transformations appear to be more successful when strategically aligned throughout the enterprise

Lean Manufacturing

Lean Manufacturing Cycles

• Identify the problem• Define major factor involved• Identify possible causes• Analyze the diagram

Cause Effect Diagram

Supporting Tools

Ishikawa diagram

Pareto Chart

thesis proposal present.pptx

Methodology

Lean

QFD

Waste

Elimination

Premilinary Survey

Study Literature

Formulation the Problem

Waste Identification

& classification

HoQ Relationship

Matrix

Make priorities of Reducing

Waste

Evaluating Standard Operation Procedure

Cause and Effect

Diagram

Creating New SOP

Type of Research• Qualitative• Case Study

Sampling Technique• Data Primer• Stratified Samples

Data Resources• Mass Production

manufacturing

METHODOLOGY

Bhim Singh, S.K. Garg, S.K. Sharma, Chandandeep Grewal, (2010),"Lean implementation and its benefits to production industry", International Journal of Lean Six Sigma, Vol. 1 Iss: 2 pp. 157 – 168

Chan, Lai-Kow., Wu, Ming Lu., (2002) “Quality function deployment: A literature review”, European Journal of Operational Research, 143 pp. 463 – 497

Holweg, Matthias, (2007) “The Genealogy of Lean Production”, Journal of Operations Management 25 pp. 420 – 437

Raharo, Hendry., Brombacher, Aarnout C., Xie, Min., (2008) “Dealing with subjectivity in early product design phase:A systematic approach to exploit Quality FunctionDeployment potentials” Computers & Industrial Engineering 55 pp. 253–278

Vatthanakul , Suteera., Jangchud, Anuvat ., et al. (2010) “Gold kiwifruit leather product development using Quality function deployment approach” Food Quality and Preference 21 pp. 339–345

Kyle B. Stone, (2012),"Four decades of lean: a systematic literature review", International Journal of Lean Six Sigma, Vol. 3 Iss: 2 pp. 112 - 132

References

Thank You