01.briefintroductiontorobustdesign68 (nxpowerlite)

7/27/2019 01.BriefIntroductionToRobustDesign68 (NXPowerLite)

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ROBUST DESIGN 1

A BRIEF INTRODUCTION TOTHE CONCEPT OF

"ROBUST DESIGN"

By Dr.N.Ramani

Principal

School of Postgraduate Studies

NTTF, Bangalore 27.Sep2006


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ROBUST DESIGN 2

Analogy between Jungles of Africa &

Todays Economy
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ROBUST DESIGN 3

Fortune 500?


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ROBUST DESIGN 4

In future there will be only two typesof Organizations: 1 & 2 ?

Tom Peters


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ROBUST DESIGN 5

Q

C

D

How?


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ROBUST DESIGN 6

Robust Design

Q

C

D

How?


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ROBUST DESIGN 7

Can there be a consumer Product

guaranteed for 100 years?


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ROBUST DESIGN 8

Can there be a pen which is

Guaranteed for 100 years?

And in addition...


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ROBUST DESIGN 9

Can there be a pen which writes

Upside down?


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ROBUST DESIGN 10


Upside down?

Under water?


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ROBUST DESIGN 11


Upside down?

Under water? Over grease?


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ROBUST DESIGN 12


Upside down?

Under water? Over grease?

In freezing cold?


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ROBUST DESIGN 13


Upside down?

Under water?

Over grease?

In freezing cold?Under boiling heat conditions?


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ROBUST DESIGN 14


Upside down?

Under water?

Over grease?

In freezing cold?

Under boiling heat conditions?

Used on all manned space flights of Americans

& Russians?


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ROBUST DESIGN 15


Upside down?

Under water?

Over grease?

In freezing cold?

Under boiling heat conditions?

Used on all manned space flights of Americans

& Russians?

& Guaranteed for 100 years?


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ROBUST DESIGN 16


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ROBUST DESIGN 17


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ROBUST DESIGN 18

Fischer Pen Development funded byNASA

Patented Pen Construction

Sealed pressurized Ink Cartridge

With Nitrogen


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ROBUST DESIGN 19


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ROBUST DESIGN 20


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ROBUST DESIGN 21


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ROBUST DESIGN 22

Article:

Watery Graves ofthe Maya

NationalGeographic

Issue Oct

2003

Pages 83-84


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ROBUST DESIGN 23

Fischer pen Anecdote betweenAmerican & Russian Astronauts


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ROBUST DESIGN 24

What makes a two-wheeler sell?

PERFORMANCE?


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ROBUST DESIGN 25

What makes a product sell (Say a two-wheeler)?

P-E-R-FORM-AN-CE

P = Price

E = Economy

R = Reliability

Form = Aesthetics

AN = And

CE = Cumulative Effect of all other parameters

like...


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ROBUST DESIGN 26

What do we see here?


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ROBUST DESIGN 27



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ROBUST DESIGN 28



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ROBUST DESIGN 29

Quality symbol is inseparable from Cost &

Delivery


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ROBUST DESIGN 30

Q

C

D


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ROBUST DESIGN 31

Design?


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ROBUST DESIGN 32

What constitutes Design?

1. Assembly For Function

2. Component Construction / Shape / Size

3. Dimensions & Tolerances

4. Features

5. Materials

6. Heat Treatment / Finish Specifications

7. Acceptance procedure...


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ROBUST DESIGN 33

DFA ?

Reason for its importance?


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ROBUST DESIGN 34

A =?

Assembly

Aesthetic Appeal

AccessibilityAccessories


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ROBUST DESIGN 35

DFA

Term coined by Geoffrey BoothroydA never ending Process?


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ROBUST DESIGN 36

DFB ?


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ROBUST DESIGN 37

DFC ?

Design for cost


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ROBUST DESIGN 38

DFD ?

Delivery

Dependability

Detail

Duty Cycle


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ROBUST DESIGN 39

DFM ?Manufacturability

Machinability

Heat-treatability

Max permissible Tolerance

MaintainabilityMaterials

Market


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ROBUST DESIGN 40

Design for SimplicityCase of a long letter

DFS ?


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ROBUST DESIGN 41

DFX ?


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ROBUST DESIGN 42

Design For A to Z


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ROBUST DESIGN 43

Design For X

DFX = (DFA to DFZ)


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ROBUST DESIGN 44

Design For X

Whichis the most important X ?


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ROBUST DESIGN 45

Design For X

Which is the most important X ?

DFC !?


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ROBUST DESIGN 46

Design For C

Which is the most important X ?

Customer designed Car!

Expansion of FORD

DFT >>>> DFM !

Domino Effect X = A to Z


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ROBUST DESIGN 47

DFX

A B CD

EF

G

H

I

JK

LM

NOP

QR

S

T

U

V

WX Y

Z

Domino Effect X A to Z

Compromise?


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ROBUST DESIGN 48

ROBUSTA?

MAN-MADE Vs GOD-CREATED

DESIGNS?


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ROBUST DESIGN 49

QUALITY PARADOX

0%

100%

Knowledge /

Expertise of our

own product !

0%

First

Proto

- Proto -Proto -Proto Time

100%

Cost of Change !


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ROBUST DESIGN 50

QUALITY PARADOX

Flexibility &

Opportunity to

improve design quality

of a new Product

0%

100%

First

Proto

- Proto -Proto -Proto Time

100%

0%


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51First

Proto

Flexibility &

Opportunity

to improvedesign

quality of a

new Product

0%

100%

Knowledge /

Expertise

of our own product !

- Proto -Proto -ProtoTime

100%

0%

Cost of Change !

QUALITY PARADOX


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ROBUST DESIGN 52

UPSTREAM

MIDSTREAM

DOWNSTREAM

SEA

AN ANALOGY OF A RIVER&..


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ROBUST DESIGN 53

AN ANALOGY OF A RIVER & A PRODUCT

WRT INFLUENCING ITS QUALITY

CUSTOMER USAGE

POST PRODUCTION

SERVICE WARRANTY

UPSTREAM

MIDSTREAM

DOWNSTREAM

SEA

PRODUCT &PROCESS

DESIGN

MANUFACTURING


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ROBUST DESIGN 54

QUALITY CONTROL

OFF - LINE

ON - LINE


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ROBUST DESIGN 55

SIGNAL Vs NOISE FACTORS


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ROBUST DESIGN 56

Variability is a fact of life

Performance of a product as measuredby QC varies in field due to NoiseFactors


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ROBUST DESIGN 57

Principle of R.D is to maximize Quality by

minimizing effects of variation withouteliminating causes

Achieved by optimizingproduct to make performance minimally

sensitive to causes of variation (Parameter

Design)


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ROBUST DESIGN 58

A classical Example

of

Earliest Application

of

Principle of Robust Design

in Japan


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ROBUST DESIGN 59

1950

Japan

INA Tile Mfg. Co

40% Rejections of Tilesafter curing


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ROBUST DESIGN 60

Schematic Arrangement of Kiln for curing tiles

Burner

Kiln Wall

Tiles


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ROBUST DESIGN 61

Analysis of Problem:

Effect: Variation of Tile dimensions

Observation:Tiles at center of Kiln

experienced a lower temperaturethan those at periphery

Cause: Non-uniformity of

distribution of temperature


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ROBUST DESIGN 62

Solution proposed by experts

A new modern kiln from USA,assuring uniform temperature

distributionCost: US$500,000

At high cost also, it madeeconomic sense, because ofrejections!


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ROBUST DESIGN 63

Robust Design Methodology

Application of principles of R.D

Eliminate the effects of noise

factors, without eliminating noisefactors

Increase in lime content from 1% to5% made the dimensional variabilitydramatically smaller!


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ROBUST DESIGN 64


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ROBUST DESIGN 65

Explanation of Principle of

Robust Design

Problem was solved by minimizing the

effect of cause of the variation

( Non-uniform temperature distribution)

without controlling the cause itself (Kiln

Design)


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ROBUST DESIGN 66

Cause - Effect Relationship

Input - Output RelationshipTrick is to find out which 20%...


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ROBUST DESIGN 67

Principle of R.D is to maximize Quality by

minimizing effects of variation withouteliminating causes

Achieved by optimizingproduct / process design

to make performance minimally sensitive

to causes of variation ( Parameter Design)

Rapid


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ROBUST DESIGN 68

Rapid & RobustDesign

RapidPrototyping

ofComponents

Rapid Tooling

Taguchi Technique todecide on the minimumnumber & treatment

combinations of trialsrequired

Rapid Testing

Relations Diagram on Rapid & Robust Design

EffectiveFMEA

DesignFor

Assembly

Design ForManufacture

3D CAD

DFX

Rapid DesignIteration
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Thank You

pgschool@nttf co in
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01.briefintroductiontorobustdesign68 (nxpowerlite)

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