beta prototype and test plan prototype and test plan module 4a key ques(ons key ques(ons ... 2 why...
TRANSCRIPT
![Page 1: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/1.jpg)
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org
BetaPrototypeandTestPlanModule4AKeyQues(ons
![Page 2: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/2.jpg)
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
![Page 3: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/3.jpg)
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
![Page 4: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/4.jpg)
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
![Page 5: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/5.jpg)
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
![Page 6: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/6.jpg)
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
o LO1.Whatarethekeyques(onstoconsiderwhendesigningandtes(ngabetaprototype?
6
LearningObjec1ves
![Page 7: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/7.jpg)
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
![Page 8: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/8.jpg)
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
![Page 9: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/9.jpg)
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
![Page 10: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/10.jpg)
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
![Page 11: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/11.jpg)
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
![Page 12: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/12.jpg)
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
![Page 13: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/13.jpg)
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
✔
![Page 14: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/14.jpg)
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
![Page 15: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/15.jpg)
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
![Page 16: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/16.jpg)
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….
![Page 17: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/17.jpg)
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
![Page 18: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/18.jpg)
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
![Page 19: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/19.jpg)
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
![Page 20: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/20.jpg)
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
![Page 21: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/21.jpg)
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
![Page 22: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/22.jpg)
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
![Page 23: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/23.jpg)
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
![Page 24: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/24.jpg)
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
![Page 25: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/25.jpg)
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
![Page 26: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/26.jpg)
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
![Page 27: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/27.jpg)
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
![Page 28: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/28.jpg)
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
![Page 29: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/29.jpg)
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.)
![Page 30: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/30.jpg)
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
![Page 31: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/31.jpg)
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
![Page 32: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/32.jpg)
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
![Page 33: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/33.jpg)
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
![Page 34: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/34.jpg)
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
![Page 35: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/35.jpg)
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
![Page 36: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/36.jpg)
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
![Page 37: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/37.jpg)
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
![Page 38: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/38.jpg)
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
![Page 39: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/39.jpg)
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
![Page 40: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/40.jpg)
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
![Page 41: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/41.jpg)
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
![Page 42: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/42.jpg)
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
![Page 43: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/43.jpg)
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
![Page 44: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/44.jpg)
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
![Page 45: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/45.jpg)
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
![Page 46: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/46.jpg)
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
![Page 47: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/47.jpg)
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
![Page 48: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/48.jpg)
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
![Page 49: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/49.jpg)
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
![Page 50: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/50.jpg)
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
![Page 51: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/51.jpg)
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
![Page 52: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/52.jpg)
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
![Page 53: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/53.jpg)
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
![Page 54: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/54.jpg)
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
![Page 55: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/55.jpg)
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
![Page 56: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/56.jpg)
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
56
Casestudy4– Automo9vebodystructuresDFMEA
o Joiningdissimilarmaterialsprocessestoproducelighterweightcars
![Page 57: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/57.jpg)
KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org
57
Exercise–DFMEAworksheetBetaPrototypeQualityPlan
![Page 58: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/58.jpg)
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
![Page 59: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/59.jpg)
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
![Page 60: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/60.jpg)
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
![Page 61: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/61.jpg)
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!
![Page 62: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/62.jpg)
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
![Page 63: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/63.jpg)
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
![Page 64: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/64.jpg)
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
![Page 65: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/65.jpg)
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
![Page 66: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/66.jpg)
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
![Page 67: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/67.jpg)
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
![Page 68: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/68.jpg)
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
![Page 69: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/69.jpg)
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
![Page 70: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/70.jpg)
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
![Page 71: Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why is this module important? Mo1va1on. Key Ques](https://reader031.vdocuments.us/reader031/viewer/2022021821/5b0587ed7f8b9ad5548b8d08/html5/thumbnails/71.jpg)
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