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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
(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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Learningobjec(veso Differencebetweenalphaandbetaprototypeso Designforfailuremodeandeffectsanalysis(DFMEA)— Whatitisandhowtouseittoyourbenefit
o Manufacturingresources
5
ModuleOutline
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o LO1.Whatarethekeyques(onstoconsiderwhendesigningandtes(ngabetaprototype?
6
LearningObjec1ves
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Whatistheexpecta(onofthecustomer,industry,ormarketformyproduct?
o WhatamIdesigningmyproductfor(e.g.,durability,serviceability)?
o Whatarethemostcommonmistakestoavoid?o HowdoIavoidthedevelopmentofseveralprototypemodifica(ons?
o WheredoIgoforprototypingservices?o Whoarethemanufacturingexpertsthatcanhelpmethroughthisprocess?
7
KeyQues9onsWhatThisModuleAddresses
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Developingaproductwithoutconsideringhowtodesignforitsopera(ngenvironment
o Launchingaproductwithoutdesigningforpoten(alfailuremodes
o Focusingonlowcostandspeedtomarketovercarefuldesignqualitymanagementanddesignformanufacturing
o Over-designingtheproductandfailingtoachievemarginspredicted
o Fallingintothetrapofredesigningaproductmul(ple(mes,whichaddstoproductdevelopmentcoststhatexhaustcompanyfundinganddelaysproductintroduc(ontomarket
Tobesuccessfulyourproductmustbeunique,butyourmanufacturingprocessshouldnotbe!
8
Commonmistakesandmisconcep9onsBetaPrototypeAndTestPlan
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Therearetwotypesofalphahardwareprototypes:o A“looks-likeprototype”thatprovidesinsighttoergonomicsandaesthe(cs
o A“works-likeprototype”thatdemonstrateskeyfunc(onalelements
o Alphahardwareprototypesareodenconsideredtobe“labexperiments”thatarenotnecessarilydesignedforthecommercialrequirements/environments
o Theydemonstratewhattheproductiscapableofdoing
9
BasicsAlphaHardwarePrototype
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Alphahardwareprototypesusekeyfeaturesofthehardwareproducttoallowpeopletointeractwithitsfunc(onalityandproposedsolu(on
o Theyareusedtoprovethatcorefeaturesoftheproductworkinadevelopmentortes(ngenvironmentunderidealcondi(ons
10
Basics(cont.)AlphaHardwarePrototype
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Betahardwareprototypesareamorepolishedversionofthekeyfeaturesofthehardwareproduct;theycanbeuseddirectlybyacustomer
o Theyarebuiltwiththeintenttoprovethatpeoplewantthesolu(onbydemonstra(ngitinthecommercialrequirements/environments— Theyareusedtoprovethatcorefeaturesworkforasmallsetofcoopera(ngbetacustomersunderless-than-idealcondi(ons
11
BasicsBetaHardwarePrototype
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Betahardwareprototypesareusedtoelicitcustomerfeedbackandgatheraddi(onaldatarela(ngtousageandfeaturesneededtobeabletosupporttweakingtheproductbeforeproductlaunch— Theycanberunprivatelyorthroughahandpickedsetofcustomersand/orstrategicpartners
o Theydemonstratethefinishedproduct,exceptforanyimportantcustomerrequirementsthathavenotyetbeendiscovered
12
Basics(cont.)BetaHardwarePrototype
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
✔
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Casestudy1-Rivetweldjoining(cont.)
TechnologyReadinessLevel
15
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
Year2progress
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Casestudy1-Rivetweldjoining(cont.)
o Whenatestfailsatareadinesslevel,thereisaneedtoretreatbackwards(odenbacktwolevels)
Example:IfthefullscaleprototypefailstobeVerifiedinOpera(ngEnvironment(MRL7),youhavetogobacktoMRL5totestopera(ngenvironments
TechnologyReadinessLevel
16
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
Year3Retreat
Year1progress
Year2progress
Ififfails….
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
ImaginethisprototypeiscurrentlyatmanufacturingreadinessMRL4andfacesthefollowingDFMorscaleupchallenges:q Some,butnotall,joiningsamplesmetcustomerqualityspecifica(ons
o Processnotrepeatableandnotprovenonavarietyofmaterialso Toomuchcustomizedtoolingo Poorunderstandingofcosttradeoffsofproposedprocessvs.exis(ngproduc(onprocesses
o Equipmentnotop(mizedformassproduc(on(automatedmaterialhandling,robo(cs)
o NoqualitycontrolmeasurementWhatac(onscanbetakentoaddressthechallengesabove?
18
Casestudy1-Rivetweldjoining(cont.)
AlphatoBetaPrototype
Source:Op9malProcessTechnologies
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
Casestudy1-Rivetweldjoining(cont.)
AlphatoBetaPrototype
Source:Op9malProcessTechnologies
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
Source:Op9malProcessTechnologies
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Lifecycle:o Howlongdoesmyproductneedtolast?o Whatdoesmyproductwarrantyneedtocover?o Whatistheexpecta(onofthecustomer?Customerusability:o Howwillmyproductbehandledbythecustomer?o Howwillitbeservicedifitrequiresmaintenanceandrepair?Logis1cs:o HowdoIneedtocareformyproductininventory?o Whatistheshelflifeofmyproduct?o Howwillmyproductbetransported?
23
Otherconsidera9onsKeyQues1ons
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Productprocesscostsarenotpredictableo Limitedpar(cipa(onorcoordina(onfromateamperspec(veo Launchismorereac(vethanproac(veo Takestoolongtolaunchtheproducto Notachievingthepredictedmarginso Overlookinglowestcostop(onsforproduc(onandassemblyo Toodependentonlowercostoverseaspartnersforqualitymanagement
o Over-promisingandunder-delivering
24
Commonmistakesandmisconcep9onsProductLaunch
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Productisengineeredwell,butcannotbeproducedo Productispoorlyengineeredbecauseadvancedsimula(ontoolswerenotused(FEA/CAE)
o Productisover-engineeredo Productmustbecompletelyredesignedo Failuretorethinkproductdesigntodriveoutcosto Productcostoverruns(i.e.,toolingandcapitolequipmentcosts)
25
Commonmistakesandmisconcep9onsProductDesign
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Processcannot“runatrate”asexpectedo Failuretoplanforeveryparto Poorpartqualityo Failuretoreduceopera(onscostsandwasteo Failuretoimprove,measure,ortrackqualityo FailuretoproperlymanageinventoryofinboundBOMoroutboundfinished-productstock
o Encounteringcapacityconstraintso Requiringmorespaceornewbuildingtoaccommodatenewsales
o Over-inves(nginopera(onsandrunningatlowcapacityrates26
Commonmistakesandmisconcep9ons
ProductProcess
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Mistakesmade:o Introducedtheproductsixteenmonthslaterthanoriginal(meline
o Sole-sourcedsuppliersandranintopartsshortageswhensupplierscouldn’tdeliver
o Tookshortcutsonqualityinspec(onofbakerypackso Finalcostofvehiclewas$20,000/carmorethantheoriginaltargetprice
o Didnotdesignproductfordurabilityandexperiencedmul(plefailuresinthefield
27
Caststudy2–Start-upelectricvehiclecompanyDevelopingBetaPrototypes
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Impact:o Companymarginswerenega(veonfirstvehiclelaunch
o Angeredpre-orderdepositcustomersbynotdeliveringvehiclebydateadver(sed
o Warrantycostskyrocketedwhenbakeriesfailedandside-impactcrashesledtolegalseklements
o Exhaustedinvestorfundsandfiledforbankruptcy
28
Caststudy2–Start-upelectricvehiclecompany(cont.)
DevelopingBetaPrototypes
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
Bestprac1ces:o Mi(gatedthecostriskbydevelopingadisciplinedapproachtocosttarge(ngfortheen(revehicleBOM
o Controlledproductop(onsandvaria(ons
o Mi(gatedsupply-chainrisksbysecuringmul(plesourcesofsuppliersforeachpart
o Mi(gatedqualityriskbyimplemen(ngDFMandcostupfrontwithinternalteamsandexternalsupplypartners
29
DevelopingBetaPrototypesCaststudy2– Start-upelectricvehiclecompany(cont.)
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
30
Bestimpact:o Companymarginswereposi(veonfirstvehiclelaunch
o Pre-orderdepositcustomershadtheirvehiclesdeliveredon(me
o Limitedfailuresexperiencedinthefield,whichcontrolledwarrantyandrecallcosts
o Receivedfollow-oninvestorfundstolaunchnewvehicleplamorms
Caststudy2–Start-upelectricvehiclecompany(cont.)
DevelopingBetaPrototypes
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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.)
DevelopingBetaPrototypes
Product:B1-aandB1-b
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
HowdoIavoidthedevelopmentofseveralprototypemodifica1ons?o Makeextensiveuseofcomputersimula(onstovalidateheattransferperformanceofvariousdesignitera(onspriortogoingtophysicalprototype
o Implementdesignformanufacturingsoonerintheengineeringanddesignprocess.Thisiswheretheindustrialdesignfirmaddedalotofvalue,asinnovatorsareodenunabletoseethemanufacturingimplica(onlandminesearlyon(chassisdesignsthatwouldop(mizeforextrusionvs.stampingprocesses).
33
Casestudy3–LEDlamp(cont.)
DevelopingBetaPrototypes
Product:B1-aandB1-b
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Theindustrialdesignfirmhadthein-housecapabili(estocreatemostofthecomponentpartsthatwereneededtomaketheproofofconceptprototype(3-Dprin(ng,CNCmachiningcapabili(es,etc.)
WheredoIgoforprototypingservices?o DFMconsul(ngfirms(suchasDragonInnova(on)o Industrialdesignfirmso Independentconsultants
34
Casestudy3–LEDlamp(cont.)
DevelopingBetaPrototypes
Product:B1-aandB1-b
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Ensurethatallteammembersarefamiliarwiththeproductanditsdesign
o Iden(fyeachofthemaincomponentsofthedesignanddeterminethefunc(onorfunc(onsofthosecomponentsandinterfacesbetweenthem
o StudyallcomponentsdefinedinthescopeoftheDFMEAo Useaprintorschema(cforthereviewo Addreferencenumberstoeachcomponentandinterfaceo Tryoutaprototypeorsampleo Inviteasubjectmakerexperttoanswerques(onso Documentthefunc(on(s)ofeachcomponentandinterface
39
Step1-Reviewthedesign
ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Reviewdocumenta(onforcluesaboutpoten(alfailuremodesbeforeundertakingbrainstormingsessions
o Usecustomercomplaints,warrantyreports,andreportsthatiden(fythingsthathavegonewrong(i.e.,holdtagreports,scrap,damage,andrework)asinputs
o Considerwhatmayhappentotheproductunderdifficultusagecondi(onsandhowtheproductmightfailwhenitinteractswithotherproducts
40
Step2-Brainstormpoten9alfailuremodes
ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Considerpoten(alfailuremodesforeachcomponentandinterface
o Apoten(alfailuremoderepresentsanymannerinwhichtheproductcomponentcouldfailtoperformitsintendedfunc(onorfunc(ons
o Manycomponentswillhavemorethanonefailuremode.Donotleaveoutapoten(alfailuremodejustbecauseitdoesnothappenoden.Documenteachone.
Don’ttakeshortcutshere;thisisthe9metobethorough
41
Step2-Brainstormpoten9alfailuremodes(cont.)
ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Aneffectoffailureisdefinedastheimpactofafailureonasystemshoulditoccur
o Theeffectisrelateddirectlytotheabilityofthatspecificcomponenttoperformitsintendedfunc(on
o Somefailureswilleffectcustomers,otherseffecttheenvironment,theproduct-produc(onprocess,andtheproductitself
42
Step3– Listpoten9aleffectsoffailure
ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Toassigndetec(onrankings,considerthedesignorproduct-relatedcontrolsalreadyinplaceforeachfailuremodeandthenassignadetec(onrankingtoeachcontrol
o Thinkofthedetec(onrankingasanevalua(onoftheabilityofthedesigncontrolstopreventordetectthemechanismoffailure
47
Step6–Assigndetec9onrankingsConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Preven(oncontrolsarealwayspreferabletodetec(oncontrols— Preven(oncontrolscomeindifferentformsandlevelsofeffec(veness
— Preven(oncontrolspreventthecauseormechanismoffailure(orthefailuremodeitself)fromoccurring;theygenerallyimpactthefrequencyofoccurrence
49
Step6–Assigndetec9onrankings(cont.)ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on:o Designofexperiments(DOE)— Powerfulsta(s(calimprovementtechniquesthatcaniden(fythemostcri(calvariablesinadesignandtheop(malsewngsforthosevariables
o Mistake-proofing— Techniquesthatcanmakeitimpossibleforamistaketooccur,reducingtheoccurrencerankingto1
— Par(cularlyimportantwhentheseverityrankingis10
52
Step8–Developtheac9onplan(cont.)ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on(cont.):o Designforassemblyanddesignformanufacturability(DFA/DFM)— Techniquesthathelpsimplifyassemblyandmanufacturingbymodularizingproductsub-assemblies,reducingcomponents,andstandardizingcomponents
o Simula(ons— Simula(onapproachesincludepre-produc(onprototypes,computermodels,acceleratedlifetests,andvalue-engineeringanalyses
53
Step8–Developtheac9onplan(cont.)ConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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.
54
Step9–Takeac9onConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Bycalcula(ngtheresul(ngRPN,thisstepinaDFMEAconfirmsthattheac(onplanhasproducedthedesiredresults
o TorecalculatetheRPN,reassesstheseverity,occurrence,anddetec(onrankingsforthefailuremodesadertheac(onplanhasbeencompleted
55
Step10–Recalculatetheresul9ngRPNConductADFMEA
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
56
Casestudy4– Automo9vebodystructuresDFMEA
o Joiningdissimilarmaterialsprocessestoproducelighterweightcars
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
57
Exercise–DFMEAworksheetBetaPrototypeQualityPlan
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
58
DFMEA/PFMEAResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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/
59
Sharedassetfacili9es/prototypingservicesManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o Gettoknowyourlocalmanufacturingextensionpartnership(MEP)
o Secureamanufacturingexpertasanadvisor,evenifitmeansprovidingsomeequity
o Takeadvantageofre(redandsemi-re(redmanufacturingexpertswhoareodeneagertosharetheirexperienceandknowledgewithinnovatorsandstartups
61
Recommenda9onsFindingManufacturingExper1se
Notsolici9nghelpfrommanufacturingexpertsisacommonmistake!
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
62
DFXTrainingResources
ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
63
DFXTrainingResources(cont.)
ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
64
DFXTrainingResources(cont.)ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
65
DFXTrainingResources(cont.)ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
66
DFXTrainingResources(cont.)ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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/
67
DFXTrainingResources(cont.)
ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
68
OtherManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
69
Other(cont.)ManufacturingResources
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
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
70
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
Top Related