Quality By Design By: Ruth Burgess, Ann LeDuc & Paula Ziegler.

Quality By DesignQuality By Design

By: Ruth Burgess, Ann LeDuc

& Paula Ziegler

Definition of:Definition of:

Quality by Design is the practice of using a

multidisciplinary team to conduct conceptual

thinking, product design, and production planning all

at one time.

A Systematic approach

to integrated product development that emphasizes

response to customer expectations

and embodies

team values of cooperation, trust and sharing

in such a manner that

decision making

proceeds with large intervals of parallel working by all life-cycle perspectives,

synchronized

by comparatively brief exchanges

to produce consensus. -- Joe Cleetus

A More General Definition

The Easy Definition!!!The Easy Definition!!!

With a team to simultaneously design and develop products that have

Ease ofProducibility

CustomerSatisfaction

Other Terms for Quality by Other Terms for Quality by DesignDesign

Concurrent Engineering

Simultaneous Engineering

Parallel Engineering

People to Include on Your People to Include on Your Quality by Design TeamQuality by Design Team Specialist From Business Engineering Production The Customer Base

and at appropriate times Suppliers of Equipment, Purchased Parts

and Services

This Front End This Front End Planning Leads toPlanning Leads to

Performance (quality & time to market) Cost

(eliminates design changes late in project)

Communication(more apt to stay flexible & eliminates

the “over the wall” mentality

Product Development Flow DiagramProduct Development Flow Diagram

Another View of a Quality Planning ProcessAnother View of a Quality Planning Process

Benefits of Quality by Design Benefits of Quality by Design

Significant decrease in time to market Faster product development Better quality Less work in progress Fewer engineering change orders Increased productivity Reduced labor costs Increased profits for the company

Teams

Must have a variety of backgrounds and expertise.

Must communicate!!

Must think outside the box-stay flexible!!

Quality by Design

Traditional Communication Flow ModelTraditional Communication Flow Model

Quality by Design Communication ModelQuality by Design Communication Model

ImplementationImplementation

Why ImplementWhy Implement

Budgets are more critical today than in past

1970’s– Fewer brands to choose from– Price = Cost + profit amount

Today– Design changes in product

development creates higher costs.


– Control cost by designing at the start of a project

– Increased time in the design stage• Changes in design stage cost 10 times more

than in testing stage• Spending 10 times more creates the need

for development software EX: CAD/CAM


More time designing results in a more complete final product

Less Rework

Less waste of Materials


Fewer Design Changes + Shorter Lead Times = Quicker Response to Customer’s Needs

Lower Rejects and Scraps = Increased Profits

Customer Returns decrease

Profit Margins increase

Key ConceptsKey Concepts

Look at the whole product life cycle

Agree that organization has internal and external customers and suppliers

Commitment to quality for the entire process of making the product

Preparation for ImplementationPreparation for Implementation

Principles - – Statement of principles that the

company operates onAssessment -

– How the company currently operates and the changes that will be made

Work Process - – Define procedures for the new process

PreparationPreparation (continued) (continued) Internal Organizational Changes -

– Define how reporting and management will change

Supply Chain - – Define how the supply chain will participate in

development of the project

People Systems - – Define reward systems, goals and objectives

Technology - – What new technology needs to be in place to

complete the project


Start– A Meeting with

everyone involved.

– Communication between everyone involved.

– Some companies start with a “Pilot”.


Benefits of Meetings– Project members meet face to face and develop

personal relationships with internal and external customers and suppliers.

– Everyone understands goals.

– Clear up misconceptions

– Answer questions


Meetings– Regular meeting should be set for reviewing the

project

– Exchange ideas and resolve complaints

– Time between meeting should be long enough for questions to arise and short enough to make design decisions


Dedicated Project Teams– Have a sense of togetherness

– Communication is established

– Each member knows the capabilities of team members


Flaws of Dedicated Project Teams– Sense of stability and settling occurs

– Tend not to look for better ways to solve problems and rely on past practices


Co-Location– Placing team members in same location

– Team stimulated to continuously find solutions to problems with the project

– Increased communication and continuous improvements


Disadvantages of Co-Location– Cost of moving and providing for

project team members

– Team members lose communication with the department they came from

– Product in that department may suffer


Computer Networks– Allow team members to

communicate with the department they came from

– Communication with resources and applications


Advantages of Computer Networks– Eliminates cost of Co-Location

– Communication between team members and outside consultants

– Records progress for managers and accounting department


Cost Increases– Time and Money have to be considered before

applying the design

Cultural Changes– Solutions require cultural changes before becoming

effective

– Through meetings, managers can slowly change the culture of the organization

– After cultural changes, project facilitator may be hired


Implementation of Quality by Design is a way to true quality by design.

TheThe ToolsTools

–A brief history

–Who uses them

–What they do

History of the ToolsHistory of the Tools

Finite element analysis developed in the 50’s and 60’s

Aircraft manufacturers start using CAD in late 1970’s

Many tools not available until late 1980’s Today, small organizations are able to buy

personal computer software tools

OverviewOverview

Organizational Tools– Improve communication and understanding

Product Development Tools– Decrease product development time

Production Tools– Improve quality of manufactured parts and decreases

production time

Statistical Tools– Allow studying and targeting of variables effecting

design, testing, and production

Who Uses the ToolsWho Uses the Tools

Organizational Tools– Everyone

Product Development Tools– Engineering and Design Professionals

Production Tools– Production Engineers

Statistical Tools– Quality Engineers and Others when needed

Organizational ToolsOrganizational Tools

TQM PhilosophyComputer NetworksISO 9000 and ISO 14000Total Productive MaintenanceQuality Function DeploymentElectronic Data Interchange

Product Development ToolsProduct Development Tools

Computer-aided drafting softwareSolid modeling softwareFinite element analysis softwareParametric analysis softwareRapid prototyping techniquesDesign for manufacture and assembly

techniquesFailure mode and effect analysis

Production ToolsProduction Tools

Computer-aided ManufacturingComputer numerical controlled toolsContinuous process improvementJust-in-time productionVirtual manufacturing softwareAgile manufacturing

Statistical ToolsStatistical Tools

Design of Experiments

Statistical Process Control

Other ConsiderationsOther Considerations

Training is a must– Requires money and time

Using the tools increases employee retention and satisfaction

Misconceptions of Misconceptions of Quality by DesignQuality by Design

It is NOT simultaneous design and production. ALL designs are finalized BEFORE production begins.

It is NOT a quick fix or magical formula for success.

It does NOT require multiple testing of products.

Should NOT be confused with TQM inspection techniques.

Pitfalls to AvoidPitfalls to Avoid

Don’t eliminate the old type sequential engineering system too quickly.

Avoid having an unobtainable schedule. Better to be done early (longer predicted time) than to be late (shorter predicted time).

Avoid using tight tolerances and stringent requirements.

Avoid changing the product specs during the design phase.

Avoid using the low bidder. Avoid automating the product development

phase before it is simplified.

ReferencesReferences

Besterfield, D. H., Besterfield, G. H., Besterfield-Michna, C., & Besterfield-Sacre, M. 1999. Total Quality Management. New York:Prentice Hall.

http://www.erim.org/cec/column/mar00.htm http://www.erim.org/cec/column/nov96.htm http://www.cerc.wvu.edu/documents.htm http://www.icsassociates.com/index.html http://www.amkor.com/services/quality/apqp.cfm

Quality By Design By: Ruth Burgess, Ann LeDuc & Paula Ziegler.

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Transcript of Quality By Design By: Ruth Burgess, Ann LeDuc & Paula Ziegler.