Quality in Product and Process Design Pertemuan 13-14 Matakuliah: Perancangan Manajemen Mutu Tahun:...

Quality in Product and Process Design Pertemuan 13-14

Matakuliah : Perancangan Manajemen MutuTahun : 2009

Bina Nusantara University 3

Chapter 7:Quality in Product and Process Design

Reference:S. Thomas Foster, “Managing Quality: An Integrative

Approach”, Second Edition, Pearson Prentice Hall, New Jersey, 2003


Quality in Product and Process Design

• Designing Product for Quality • Quality Fuction Deployment (QFM) • Technology in Design • Prototyping Methodologies • Design for Reliability • Environmental Consideration in Design• Discussion and Questions


Designing Product for Quality

• In design product we must first many Questions• What does it mean to design products for Quality


Project Development Process

• Product idea generation• Customer future needs projection• Technology selection for product• Technology development for process selection• Final product definition• Product market and distributioaration• Product design and evaluation• Manufacturing system design• Product manufacture, delivery and use(See Figure 7-1, Project Development Process)


Quality Fuction Deployment (QFM)

• See Figure 7-2, QFD Layout: The House of Quality:– Technical Requirements– Customer Requirements– Competitive Assigment


The Steps in Performing a QFD

• Develop a list customer requirement• Develop a list of technical design elements along the roof of

the house• Demonstrate the relationships between the customer

requirements and technical design elements.• Perform a competitive assessment of the customer

requirements• Prioritize customer requirements• Prioritize technical requirements• Final evaluation


Technology in Design

• Computer Aided Design (CAD) system– Multiuser CAD Systems– Geometric Modeling– Engineering Analysis– Design Review– Interface Checking– Group Technology

• Computer Aided Inspection (CAI)• Computer Aided Testing (CAT)


Prototyping Methodologies

• Organizing the Design Team• The Product Life Cycle• Product Families and the Product Life Cycle (See

Figure 7-13, Cumulatives Product Family Life Cycle)

• Complementary Products• Design for Manufacture (DFM)• Design for Maintenability


Design for Reliability

• Failure Modes and Effects Analysis (FMEA)– Improvement of the safety, quality, and the realibility of

product– Improvement of a company’s image and its competitiveness– Increased satisfaction from user standpoint– Reduction in product development cost– Record of actions taken to reduce a product risk


FMEA Steps

• Assign each component an identifier• List functions for each part• List one or two failure modes for each fuction• Describe effects of each failure mode• Determine hazards likelihood and catagorieze• Estimate likelihood of failure• Estimate failure detection• Identify hightest risk• Elimanate or reduce highest risk



• Reliability Analysis Tools– Failure Modes and Effects Analysis (FMEA)– Fault Tree Analysis – Failure Modes, Effects, and Criticality Analysis (FMECA)



• Failure Modes and Effects Analysis (FMEA)– Method for systematically considering each component of a

system, identifying, analyzing, and documenting the possible failure modes within a system and the effect of each failure on the system.

• Benefits of FMEA– Improvement of product safety, quality, and reliability.– Improvement of a company’s image and competitiveness.– Increased satisfaction from a user standpoint.– Reduction in product development cost.– Record of action taken to reduce a product risk.



• Basic areas where FMEA can be applied– Concept: FMEA is used to analyze a system or its subsystems in

the conception of the design.– Process: FMEA is applied to analyze the assembly and

manufacturing processes.– Design: FMEA is used for analysis of products before mass

production of the product begins.– Service: FMEA is used to test industry processes for failure prior

to their release to customers.– Equipment: FMEA can be used to analyze equipment before the

final purchase.



FMEA Steps Figure 7.18



• Fault Tree Analysis– An analytical tool that graphically renders the combinations of

faults that lead to the failure of the system. – This technique is useful for describing and assessing the events

within a system.

• Primary Symbols of Fault Tree Analysis– Events– Gates

• Gates– Link the faults to the undesired events within the diagram.

Gates show how faults are related.



• Types of Events (in Fault Tree Analysis)– Basic events are initiating faults that do not require events below

them to show how they occurred. The symbol used for a basic event is a circle.

– An intermediate event is the result of a combination of faults, some of which may be primary events.

– This intermediate event is located in the middle of a fault tree. These events are described by rectangles.

– An expanded event requires a separate fault tree because of its complexity. For this new fault tree, the expanded event is the undesired event and would be located at the top of the fault tree.



Fault Tree Diagram

Figure 7.20



• Steps in Fault Tree Analysis– Become familiar with the system.– Define the undesired events of the system with the related

contributing and initiating events.– Develop fault trees for the undesired events.– Obtain probabilities for the events on the fault trees.– Evaluate fault trees.– Analyze the results and proposals for system improvement.– Change the fault trees to reflect proposed improvements

and renewed fault tree evaluation.– Perform a worst case analysis.



• Failure Mode, Effect, and Criticality Analysis (FMECA)– An extensive, but simple method for identifying ways in which

an engineered system could fail.

• Criticality– In FMECA is important because it prioritizes how the design

team should be spending its resources.– In general, criticality refers to how often a failure will occur,

how easy it is to diagnose, and whether it can be fixed.– Critically assessment is somewhat subjective because it

depends on the viewpoint of a service or field analysis.



• Product Traceability– The ability to trace a component part of a product back to its

original manufacturer.

• Consumer Product Safety Commission (CPSC)– An independent federal regulatory agency that helps keep

American families safe by reducing the risk of injury or death from consumer products.


Environmental Conditions in Design

• Importance– Currently, society demands much more from product designers

than just high-quality products. Many manufacturers have turned to a more environmental form of manufacturing that offers positive returns on investment.

• Green Manufacturing– Movement that began in Germany with requirements for

importers to remove packaging materials.


Environmental Conditions in Design

• Design for Reuse– Designing products so they can be used in later generations of

products.• Design for Disassembly

– A method for developing products so that they can easily be taken apart.

• Design for Remanufacture– A method for developing products so that they parts can be used

in other products. Associated with green manufacturing.


Discussion and Questions

• Case 7-1:– Designing the Ford Taurus: Why Quality Had to be Job 1

• Case 7-2:– Nucor Corporation: Producing Quality Steel by Stressing

Sound Management Practices

Quality in Product and Process Design Pertemuan 13-14 Matakuliah: Perancangan Manajemen Mutu Tahun:...

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