Post on 31-Dec-2015
description
QUALITY BY DESIGN
Quality Function Deployment
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 1
TOTAL QUALITYQualitas adalah segala keseluruhan karakteristik dari sebuah entiti yang berdasarkan pada kemampuan barang/produk tersebut untuk memenuhi kebutuhan baik yang tersirat maupun yang tidak.
(ISO/DIS 8402-1991 )
Bergantung pada kedalaman dari lingkup aplikasinya, ISO telah menggariskan tiga standar dimana qualitas dapat dipenuhi, yaitu :
ISO 9001 : Quality system, Model for quality assurance in design/development, production, installation ad servicingISO 9002: Quality system – model for quality assurance for production, and
installationISO 9003: Quality system – model of quality assurance in final inspection and
tests.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 2
TOTAL QUALITYQUALITY ENGINEERING
OFF-LINE QUALITY CONTROLEngineering Optimisation using statistical methods
Product Design(Product Optimisation)
Process Design(Process Optimisation)
System Design Innovation
Parameter Design Optimisation
Tolerance Design Optimisation
ON-LINE QUALITY CONTROLProcess control
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 3
TOTAL QUALITY
ON-LINE QUALITY CONTROL
Refers to activities that monitor quality characteristic during or after production and define the statistical rules for determining whether actions should be taken to correct changes in he underlying process
PROCESS CONTROL
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 4
TOTAL QUALITYOFF-LINE QUALITY CONTROL
Refers to activities that occur during product and process design stage.
Quality by design means that a structured off-line methods are used to determine the design configuration that meet customers need and are robust
Engineering Optimisation Using Statistical Methods
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 5
TOTAL QUALITYOFF-LINE QUALITY CONTROL
ROBUST : product performance characteristic are insensitive to variation in manufacturing and operating environments.Robustness by design reduces the need of the company to rely on extensive monitoring and controls
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 6
TOTAL QUALITYOFF-LINE QUALITY CONTROL
Quality Function Deployment TAGUCHI Method
A structured process for taking the needs and desires of the customers and translating them into technical engineering requirements
Incorporates variability measures and technical requirement generated from customers input into the evaluation of alternative product designCreate robust design
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 7
SYSTEM DESIGN INNOVATION QUALITY FUNCTION DEPLOYMENT
Quality Function Deployment (QFD) is a systematic approach for the design of new product or services based on close awareness of customer desires coupled with integration of corporate functional groups
This approach is a set of planning and communication techniques that focus and coordinate organisational capabilities in order to develop products that most closely meet customer’s actual needs
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 8
QFD can be seen in two lights :
1. As a comprehensive organisational mechanism for planning and control new product development
2. As localised techniques to translate the requirement of one functional group into the supporting requirement of a downstream functional group.
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 9
QFD requires multifunctional team of expert to participate simultaneously in a complex analytic exercise, bringing diverse perspective to bear on key issues of design
In localised usage, QFD serves both technical and organisational function
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 10
PRIMARY EXPECTED OUTCOMES :
1. Increased awareness of customers desires,
improved product with focus on actual customer
wants, improved product specification setting
and in general more succesful and effective product
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 11
PRIMARY EXPECTED OUTCOMES :
2. Synergistic gain resulting from integration of
and increased effective communication between
individuals from different groups.
Such gains include understanding of each other
functional constraints and capabilities and transfer
of information earlier
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 12
PRIMARY EXPECTED OUTCOMES :
3. Effective definition and prioritisation of new product
development activities
leading to increased understanding of trade-offs,
clear understanding of product objectives and
customer needs,
improves decision making,
a better end product
and reduced development time
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 13
QUALITY FUNCTION DEPLOYMENT
Quality Function Deployment (QFD) is a set of planning and communication routines that focuses and coordinates skills within an organisational first to design, then to manufacture and market goods that customers want to purchase and will continue to purchase “ [Hauser&Clausing]
It aims at stimulating and structuring this multidisiplinary communication.
QFD supports a project team in identifying the needs of the custumer and interpreting them in term of technical parameters and target values Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 14
QUALITY FUNCTION DEPLOYMENT
PRODUCT ATTRIBUTES
PRODUCT EVALUATION
PROJECT OBJECTIVES
ENG CHARACTERISTIC
INTERACTION MATRIX
PARAMETERS INTERACTION
TECHNICAL ANALYSIS AND TARGET VALUS
FEASIBILITY
DEVELOPMENT PLAN
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 15
QUALITY FUNCTION DEPLOYMENT
PRODUCT ATTRIBUTES
Product attributes reflecting the wishes of the customer. The attributes should be based on the voice of the customers.
To obtain such collection of product attributes, creativity techniques can be used as well as data obtained from through market and consumer research, document of complaints and repairs, trend analysis and earlier QFD analyses.
In applying QFDfor the first time, it is adviseable to divide the step into 4 steps i.e Generate, Select, Classify, and structure
The last part, the relative importance of product attributes is compared and weighted
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 16
CUSTOMER NEED ANALYSIS
• Need analysis is concerned with establishing the true needs of the customer – the ‘voice of the customer’- (VOC).
• This can be obtained by extensive examination of the views and reports of representative bodies, market data publications (buying habits), reports giving official opinions and reactions to products in use and also by structured interviews or customer questionnaires.
• The establishment of customer need is important. Ideally, needs analysis should be approached by structuring interview schedules or questionnaires around the element of the PDS.
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 17
CUSTOMER NEED ANALYSIS
• The PDS primary elements should form the triggers for asking the right questions of customers and so structured the analysis will naturally from the basis for the PDS itself
• This is to be preferred to random approaches to ascertain customer needs, which tend to leave fundamental gaps in the information gathered. This happens particularly if the questions themselves are derived and driven from consideration of existing products and customers views of those products rather than from fundamental needs issues.
QUALITY FUNCTION DEPLOYMENT
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 18
QUALITY FUNCTION DEPLOYMENT
PRODUCT EVALUATION
This step, assumes that the organisation involved has a comparable product on the market for the specific target group.
Performance of the current product is submitted to an evaluation, by competitive bench-marking. The earlier obtained product attributes are used as evaluation criteria.
For each evaluation criterion it is accertained whether the product is better, similar or worse that the competitive products all this seen from the customer’s prespective.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 19
QUALITY FUNCTION DEPLOYMENT
PROJECT OBJECTIVES
The evaluation provides an insight into the problems regarding the function of the current product.
Combining these performance data with relative importance of the product attributes is useful in assessing the opportunities for improvement of the product and in determining the project objectives.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 20
QUALITY FUNCTION DEPLOYMENTENGINEERING CHARACTERISTIC
In this step, the new product is described in terms of engineering characteristic.
These characteristic here called “Technical Parameters” and the measurement of units can be based on the specifications of the forerunners of the product or can be derived by operationalisation of the product attributes
Measureability of the parameters is seen as very important.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 21
QUALITY FUNCTION DEPLOYMENT
MATRIX INTERACTION
The project objectives from steps 3 are subsequently translated into priorities for the technical parameters.
This steps form the core of the QFD method as the technical parameters can be linked to various product attributes, in a matrix the product attributes (what) are set off against the technical parameter (how) Subsequently, it is determined for each cell of the matrix whether there is a relationship or not, and if so , what is the strength of this relationship.The completed matrix provides the operationalisation of the product attributes, and is tool for determining the priority of the technical parameters
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 22
QUALITY FUNCTION DEPLOYMENT
INTERACTION BETWEEN PARAMETERS
Changing parameters can influence one or more other parameters.
It is important to make the nature and strength of these interaction explicit before generating solution to improve one or more specific parameters of the product.
In a second matrix, the so called “the roof of the House of Quality” the interaction between the parameters can be laid down.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 23
QUALITY FUNCTION DEPLOYMENT
TECHNICAL ANALYSIS AND TARGET VALUES
The current product and competitive products are being analysed to established the parameter values of various products.
This comparison provides an insight into the possibility for improvement of the product and can help to set target values to be pursued.
The inventory of possible improvement also provides a test for consistency of interaction matrix and the project objectives as it must be possible to align the results of the technical analysis through the interaction matrix with the results of product evaluation
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 24
QUALITY FUNCTION DEPLOYMENT
FEASIBILITY
In general, one will seek improvement of those parameters for which the competitive products score better than the own product.
The feasibility, however, of an improvement depends on the knowledge and skills of the people in the organisation, the available development capacity and the available production process.Therefore it is useful to estimate the degree of complexity or the costs of an improvement
Finally, based on the priorities, feasibility and the mutual relationship between parameters, it has to be decided on which parameter and target values in the product development project will focus
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 25
QUALITY FUNCTION DEPLOYMENT
DEVELOPMENT PLAN
The final results of QFD method is a development plan for the product involved.
This plan lays down the target values(requirement) for technical parameters and is tailored to the development capacity available for the project.
Parameter which because of feasibility do not yet qualify for improvement can give direction to R&D activities in the long term
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 26
CASE 1 : OF QFD
APPLICATION OF QFD ON ATTACHE CASE
The case is based on fictional problem : the improvement of an attache case,
The example served as an illustration only, not every steps is worked in detail
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 27
CASE 1 : OF QFD
APPLICATION OF QFD ON ATTACHE CASE
The case is based on fictional problem : the improvement of an attache case,
The example served as an illustration only, not every steps is worked in detail
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 28
CASE
1. CUSTOMER VOICE :
Determine what the customer considers important in a case
By Mean-end analysis attributes can be refined
Weighing factors shows the relative importance of product
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 29
CASE
1. CUSTOMER VOICE :Product Attributes Importance- Easy to carry 2- Easy to open 4- Easy to find contents 4- Adjustable capacity 1- Easy to Close 3- Durable 5- Stable when standing 3- Privately accessible 2
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 30
CASE
2. PRODUCT EVALUATION:
• A systematic comparison of our product with that of our competitor in the eye of our customers
• The product evaluation shows the potential improvement of our product
• Strong and weak point of our design
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 31
CASE
2. Product Evaluation:
Product Attributes- Easy to carry- Easy to open
- Easy to find contents- Adjustable capacity
- Easy to Close- Durable
- Stable when standing - Privately accessible
1 2 3 4 5
Our Product Competitive Product
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 32
CASE
3. Project Objectives:
• Determining the aspects to improve involves strategic choices for relative importance of the product attributes
• For attributes which do not need improvement, the target value is equal to the evaluation score of current product
• The improvement rate relates the desired improvement to the current performanceImprovement rate = target value/evaluation score
• Weight of each product is calculated Weight = importance x improvement rate
• Normalising the weighing scores into percentageProduct DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 33
CASE
3. Project Objectives:
Product Attributes- Easy to carry- Easy to open
- Easy to find contents- Adjustable capacity
- Easy to Close- Durable
- Stable when standing - Privately accessible
Tar
get V
alue
Impr
ovem
ent R
ate
Wei
ght
Wei
ght (
%)
455
1.72.5
6.8 2010 30
61 2
44443
11.3111
13.9532
3121596
1 2 3 4 5
33.7 100
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 34
CASE
4. Technical Parameters: • Voice of the Engineers• Translate the subjective customers statement into objective
engineering performance measure• QFD team must create a lists of technical measurement that
are most likely to predict the degree to which a need will be fulfilled (Mean-End hierarchy)
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 35
CASE
4. Technical Parameters:
- Volume 394 cm3
- Safety Lock Type X- Empty Weight 2.4 Kg- Opening Steps 6 steps- Segment 5 segment- Material Type K- Angle of Opening 80 degree- Closing force 0.045 N- Wear of lock 5000 cycle
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 36
CASE
5. Matrix Interaction :
• Relation between the product attributes and technical parameter are investigated
• How strong is the relation for each cell• A score of importance or the parameter-attribute is obtained by
Score = Strength of relationship x weight of attribute • The sum of these scores per column indicates the priority of the
technical parameters for the project
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 37
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 38
5. Matrix Interaction
Tec
hn
ical
Par
amet
ers
- V
olu
me
- S
afet
y L
ock
- E
mpt
y W
eigh
t
- O
pen
ing
Ste
ps
- S
egm
ent
- M
ater
ial
- A
ngl
e of
Ope
nin
g
- C
losi
ng
forc
e
- W
ear
of lo
ck
Product Attributes - Easy to carry- Easy to open
- Easy to find contents- Adjustable capacity
- Easy to Close- Durable
- Stable when standing - Privately accessible
Importance
54 6 6
60 180 20 60
30 270 90
27 9 9 9
36 108 36
15 135 135 45 135
27 27 9
54 18 6
2
4
4
1
3
5
2
3
138 150 57 333 305 150 99 153 231 1616
9 9 4 21 19 9 6 9 14 100
Sum Scores
Priority (%)
Strong relationship = 9
Medium Relationship =3
Weak Relationship = 1
Wei
ght (
%)
2030
6
3121596
• Technical trade-offs• If one technical feature is improved, is there a strong
possibility that another will also improve ? If yes then
POSITIVE correlation exists• Alternatively, If one technical feature is improved, is there
a strong possibility that another will get worse ? If yes then
NEGATIVE correlation exists• Knowing the relationship and the priority for each technical
parameter the company must approach the conflict as an
opportunity for technical breakthrough.
6. Interaction Between Technical Parameters:
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 39
Technical Parameters
- Volume
- Safety Lock
- Empty Weight
- Opening Steps
- Segment
- Material
- Angle of opening
- Closing force
- Wear of lock
6. Interaction Between Technical Parameters:
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 40
• On the basis of technical parameter, another comparison and
evaluation should be carried out
• On the basis of the technical data and the priorities of the
parameter the target values are now being determined
• A group of related technical parameters with these target
values can then be submitted as PDS to a relatively
independent design assignment team of designers
7. Technical Analysis and Target
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 41
Tec
hn
ical
Par
amet
ers
- V
olu
me
- S
afet
y L
ock
- E
mpt
y W
eigh
t
- O
pen
ing
Ste
ps
- S
egm
ent
- M
ater
ial
- A
ngl
e of
Ope
nin
g
- C
losi
ng
forc
e
- W
ear
of lo
ck
416 y 2.2 4 6 l 85 0.32 3500
394 x 4 2 8 k 80 0.45 5500
Competitive Product
Target Value
cm3 type kg # # type deg N #
394 x 2.4 6 5 k 80 0.45 5000
Measurement Unit
Our Product
7. Technical Analysis and Target
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 42
9. Development Plan :
• The design team will have to pay attention to the factor that
will improve the overall quality of product
• In this case of attache case, the designer need to work on
• reducing the the steps necessary to open the case to a
target value of 2.
• Increasing the segment into 8
• and increasing the wearnes of the lock to 5500 cycles.
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 43
HOUSE OF QUALITY
138 150 57 333 305 150 99 153 231 1616
9 9 4 21 19 9 6 9 14 100
Sum Scores
Priority (%)
416 y 2.2 4 6 l 85 0.32 3500
394 x 4 2 8 k 80 0.45 5500
Competitive Product
Target Value
cm3type kg # # type deg N #
394 x 2.4 6 5 k 80 0.45 5000
Measurement Unit
Our Product
Tec
hnic
al P
aram
eter
s
- V
olum
e
- Sa
fety
Loc
k
- E
mpt
y W
eigh
t
- O
peni
ng S
teps
- Se
gmen
t
- M
ater
ial
- A
ngle
of
Ope
ning
- C
losi
ng f
orce
- W
ear
of lo
ck
Product Attributes - Easy to carry- Easy to open
- Easy to find contents- Adjustable capacity
- Easy to Close- Durable
- Stable when standing - Privately accessible
Impo
rtan
ce
54 6 6
60 180 20 60
30 270 90
27 9 9 9
36 108 36
15 135 135 45 135
27 27 9
54 18 6
2
4
4
1
3
5
2
3
Tar
get V
alue
Impr
ovem
ent R
ate
Wei
ght
Wei
ght (
%)
1 2 3 4 5
45
5
1.7
2.5
6.8 2010 30
61 2
44
4
4
3
11.3
1
1
1
1
3.95
3
2
3
1215
9
633.7 100
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 44
HOUSE OF QUALITY
138 150 57 333 305 150 99 153 231 1616
9 9 4 21 19 9 6 9 14 100
Sum Scores
Priority (%)
416 y 2.2 4 6 l 85 0.32 3500
394 x 4 2 8 k 80 0.45 5500
Competitive Product
Target Value
cm3type kg # # type deg N #
394 x 2.4 6 5 k 80 0.45 5000
Measurement Unit
Our Product
Tec
hnic
al P
aram
eter
s
- V
olum
e
- Sa
fety
Loc
k
- E
mpt
y W
eigh
t
- O
peni
ng S
teps
- Se
gmen
t
- M
ater
ial
- A
ngle
of
Ope
ning
- C
losi
ng f
orce
- W
ear
of lo
ck
Product Attributes - Easy to carry- Easy to open
- Easy to find contents- Adjustable capacity
- Easy to Close- Durable
- Stable when standing - Privately accessible
Deg
ree
of I
mpo
rtan
ce
54 6 6
60 180 20 60
30 270 90
27 9 9 9
36 108 36
15 135 135 45 135
27 27 9
54 18 6
2
4
4
1
3
5
2
3
Tar
get V
alue
Impr
ovem
ent R
ate
Wei
ght
Wei
ght (
%)
1 2 3 4 5
45
5
1.7
2.5
6.8 2010 30
61 2
44
4
4
3
11.3
1
1
1
1
3.95
3
2
3
1215
9
633.7 100
WHAT
HOW
RELATIONSHIPMATRIX
COMPETITIVEASSESMENT
CORRELATIONMATRIX
HOW MUCH
COMPETITIVEASSESMENT
IMPORTANCE RATING
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 45
QFD FLOW
ManufacturingOperation
Part
Cha
ract
eris
tic
PartCharacteristic
Des
ign
Req
uire
men
ts
Design Requirements
Cus
tom
er
Req
uire
men
ts
ProductionRequirement
Man
ufac
turi
ngO
pera
tion
Product DevelopmentDr A. Riza Wahono : “ Qualitas krn Desain ” modul 5 46