Integration of VECTOR & Next-Generation DfLSS
for Fast Innovation within ARDEC
VECTOR Detail Design: The Application of
Axiomatic Design
Dr. Basem Haik, President
Six Sigma Professionals, Inc. (SSPI)
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 1
(734) 765-5229
Dr. Basem Haik
• President, Six Sigma
Professionals, Inc. (SSPI)
• Web: www.SixSigmaPI.com
• Mail:
Six Sigma Professionals, Inc. (SSPI)
39505 Dorchester Circle
Canton, Michigan 48188 USA
• Email:
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 2
Professionals, Inc. (SSPI)
• Background: Ph.D. (WSU)&
Doctor of Manfg. (UOM), 20 yrs in
Prod. Dev./RD, Tech. Specialist @
Ford, SSPI President
• Experience / Key Clients:
Cessna, Bell Helicopter, Baxter,
GM, Textron Systems, …
• 6 Authored DFSS Texts (+ 2
forthcoming + many papers)
• Email:
• Tel.: (734) 765-5229 (USA)
• Fax: (734) 728-8507 (USA)
Objective
• Introduce Axiomatic Design Methodology (HL Intro)
• Explain how Axiomatic Design was used in Vector
Detail Design phase
• Demystify the linkages to Computer-Aided DFSS
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 3
What is an “AXIOM”?
• An “axiom”, in mathematics and logic, is a general
statement accepted without proof as the basis for logically
deducing other statements (e.g. corollaries and theorems),
which later form a logical system of its own.
• Axioms widely used are those related to engineering and
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 4
• Axioms widely used are those related to engineering and
mathematical operations– Newton laws - Archimedes' Axiom - Euclidean geometry
– Thermodynamics - Field Axiom
– Probability Axioms (e.g. the associative law and the commutative law of set
theory)
An axiom , a postulate, is a self-evident statement without proof, but the truth of the statement need not be readily evident.
What is an “AXIOM”? (cont’d)
• An axiomatic system is valid and sustained if the set
of axioms satisfy the following attributes:
– The set of axioms are independent; i.e., no one axiom
statement may be deduced from any combination of the
others.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 5
others.
– The axioms are consistent, i.e., it is not possible to
deduce contradictory theories and corollaries from them.
– The axiomatic set is complete; i.e., any true statement
within the system may be deduced from the axioms.
Axiomatic System Example: Newton’s Laws
• Newton LAW I.
– Every body perseveres in its state of rest, or of uniform
motion in a right line, unless it is compelled to change that
state by forces impressed thereon.
• Newton LAW II.
– The alteration of motion is ever proportional to the motive
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 6
– The alteration of motion is ever proportional to the motive
force impressed; and is made in the direction of the right
line in which that force is impressed.
• Newton LAW III.
– To every action there is always opposed an equal reaction;
or the mutual actions of two bodies upon each other are
always equal, and directed to contrary parts.
Axiomatic System Example: Laws of
Thermodynamics
• First law
– In any process, the total energy of the universe remains the same
OR
– for a thermodynamic cycle the sum of net heat supplied to the
system and the net work done by the system is equal to zero.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 7
• Second law
– The entropy of an isolated system not in equilibrium will tend to
increase over time, approaching a maximum value at equilibrium.
• Third law
– As temperature approaches absolute zero, the entropy of a
system approaches a constant minimum.
Axiomatic System Example: Laws of
Thermodynamics
• First law
– In any process, the total energy of the universe remains the same
OR
– for a thermodynamic cycle the sum of net heat supplied to the
system and the net work done by the system is equal to zero.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 8
• Second law
– The entropy of an isolated system not in equilibrium will tend to
increase over time, approaching a maximum value at equilibrium.
• Third law
– As temperature approaches absolute zero, the entropy of a
system approaches a constant minimum.
Axiomatic System Example: Euclidean
Geometry (cont’d)
• Euclidean geometry is an axiomatic system, in which all theorems
("true statements") are derived from a finite number of axioms. Near
the beginning of the first book of the Elements, Euclid gives five
postulates (axioms):
1. Any two points can be joined by a straight line.
2. Any straight line segment can be extended indefinitely in a straight line.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 9
2. Any straight line segment can be extended indefinitely in a straight line.
3. Given any straight line segment, a circle can be drawn having the segment
as radius and one endpoint as center.
4. All right angles are congruent.
5. Parallel postulate. If two lines intersect a third in such a way that the sum of
the inner angles on one side is less than two right angles, then the two lines
inevitably must intersect each other on that side if extended far enough.
Axiomatic System Example: Field
Axioms
• A field is a set F with binary operations + ("plus") and . ("times") that obey the
following axioms:
– Law of closure: If a; b belong to F then a + b and a . b (or ab = a . b ) are both in F.
– Commutative Law: If a; b belong to F then a + b = b + a and a . b = b . a.
– Associative Law: If a; b; c belong to F then a + (b + c) = (a + b) + c and a . (b . c) = (a
. b) . c.
– Distributive Law: If a; b; c belong to F then a(b + c) = ab + ac.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 10
– Distributive Law: If a; b; c belong to F then a(b + c) = ab + ac.
– Existence of identities: There exist distinct elements (denoted by) 0 and 1 in F such
that for every a belong to F: 0 + a = a and 1 . a = a. We call 0 and 1 the additive identity
and the multiplicative identity, respectively.
– Existence of inverses: • Additive inverse: If a belongs to F then there exists an element b belong to F such that b + a = 0 (we call b
an additive inverse of a.)
• Multiplicative inverse: If a belongs to F and a ≠ 0 then there exists an element b belongs to F such that b.a
= 1 (we call b a multiplicative inverse of a.)
What Is Axiomatic Design?
• Axiomatic Design (AD) is a general principle for design analysis and
design synthesis developed by Prof. Nam P. Suh of MIT.
Axioms are general principles or self-evident truths that cannot be derived or proven to be true except that there are no counter-examples or exceptions to
prove otherwise.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 11
“ The goal of axiomatic design is many fold: to make human designers
more creative, reduce the random search process, minimize the
iterative trial and error process, and determine the best design
among those proposed.”
Prof. Nam Suh
Designer Psychological Inertia
Current Practice:
• Novel ideas in engineering and business are mostly produced by the trial-and-error method.
• No rules for systematic solution generation, and the process is often stochastic.
• If an idea is weak initially, it is discarded, and a new idea is suggested.
• The flow of ideas is uncontrollable, and
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 12
• The flow of ideas is uncontrollable, and attempts (trials) are repeated as many times as needed to find a solution.
• Psychological inertia sources:
• Perceptual (stereo-typing)
• Cultural (taboos, tradition)
• Emotional (fear of change)
• Environmental (autocratic supervisors)
• Intellectual/Expressive
Although seemingly random, most trials have a common attribute: they are more numerous along a so-called vector of psychological inertia.
Axiomatic Design
• Axiom 1: The Independence Axiom
– A good design comprises of Design Parameters (DPs) that maintain the
independence of functional requirements (FRs)
• Axiom 2: The Information Axiom
– Among the designs that satisfy Independence Axiom, the best design is
one that requires the least amount of “information” to achieve the design
goal.
Violation of
Axiom 1
Violation of
Axiom 2
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 13
• Over 40 corollaries and theorems were derived from these two axioms.
Conceptual Quality
Do we have the RIGHT concept?
OperationalQuality
Do we develop the concept RIGHT?+
Axiomatic Design develops CONCEPTUAL & OPERATIONAL IMMUNITY
Axiom1 Axiom2
Axiomatic Design (cont’d)
FR1: Control the flow of water
FR2: Control the temperature of waterDP1:Angle of valve 1
DP2: Angle of valve 2
Functional Requirements Design Parameters
Hot water Cold water Hot water Cold water
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 14
Hot water Cold water Hot water Cold water
Source: El-Haik, B., “Axiomatic Quality & Reliability”, John Wiley & Sons, Inc., New York, April, 2005.
DP2
DP1 DP2
DP1
Example of Independence Axiom: Example of Independence Axiom: Example of Independence Axiom: Example of Independence Axiom:
Water FaucetWater FaucetWater FaucetWater Faucet
DP2
DP1
Hot water Cold water
DP2
Hot water Cold water
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 15
DP1
××××
=
==
2
1
eTemperaturControl FR2
FlowControl FR1
DP
DP
Coupled Design(DPs create conflicting functions)
Uncoupled Design(DPs maintain independence of functions)
××
=
==
2
1
0
0
eTemperaturControl FR2
FlowControl FR1
DP
DP
Example of Independence Axiom:
Water Faucet (cont’d)
DP2222DP1111
Hot water Cold waterIn E
l-Ha
ik, B
., “Axio
ma
tic Qu
ality
& R
elia
bility
”, Joh
n W
iley
& S
on
s, Inc., N
ew
Yo
rk, A
pril,
20
05
.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 16
Coupled Design(DP’s create conflicting functions)
=
2
1
2
1
DP
DP
X
X
FR
FR
Violation of
Axiom 1
Ha
ik, B
., “Axio
ma
tic Qu
ality
& R
elia
bility
”, Joh
n W
iley
& S
on
s, Inc., N
ew
Yo
rk, A
pril,
20
05
.
Coupling is BAD!
X
X
Corollary No. 3: : Beverage can design
matrix
FR1= Need to fill can
FR2= Need to seal can
FR3= Need to re -
DP1= Open top drawn container
DP2= Cold welded lid
DP3= Tear away
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 17
FR3= Need to re -open can
DP3= Tear away strip in lid
=
3
2
1
3
2
1
33
21
11
DP
DP
DP
A
A
A
FR
FR
FR
0
0
Auto Lift Gate Design Example
Structural Rigidity A11 0 0 0 0 0 Mass, Geometry, Moment of Inertia
Easy to Open A21 A22 A23 0 0 0 Gate Strut, Hinge
Easy to Close = A31 A32 A33 0 0 0 Gravity, Hinge
Seal 0 A42 0 A44 0 0 Weather-strip, Seal gap
Stay Latched 0 0 0 0 A55 0 Latch strength, friction
Low Closing Speed 0 A62 0 A64 A65 A66 Airbinding
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 18
Nayak, R., Im, K.H., Lin, C.L., and Kapadnis, P. (2002) “Robust design of liftgate opening/closing efforts,”
Int. Journal of Materials & Product Technology, Vol 17, Nos. 5/6, pp.368-374.
FR1
FR2
DP1
DP2
(1)
(2)
FR1
FR2
(1)
(2)
DP1
DP2
FR1
FR2
DP1
DP2
(1)
(2)
Coupling Vector Representation
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 19
Coupled DesignSequence Dependent
FR1 DP1
FR2 DP2=
Full Matrix[ ]
FR1
Decoupled DesignSequence Dependent
FR1 DP1
FR2 DP2=
Triangular Matrix [ ]
FR1
Uncoupled DesignSequence Independent
FR1 DP1
FR2 DP2=
Diagonal Matrix [ ]
Coupling Could Happens Across Design Hierarchy
Independence of Functional
Requirements
Uncoupled Decoupled Coupled
=
3
2
1
00
00
00
3
2
1
DP
DP
DP
X
X
X
FR
FR
FR
=
3
2
1
0
00
3
2
1
DP
DP
DP
XXX
XX
X
FR
FR
FR
=
3
2
10
3
2
1
DP
DP
DP
XXX
XXX
XX
FR
FR
FR
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 20
More Ideal Less Ideal
• A is non-zero quantity, signifying the fact that there is a strong relationship between FR and the
corresponding DP
• 0 means there is no relationship between them
Axiom1: Design Analysis
• FR1: Freeze food for long-term
preservation
• FR2: Maintain food at cold
temperature for short-term
preservation
• DP1: Freezer section
• DP2: Refrigerator section
• DP11: Turn on and off the compressor
Zig
Zig
Zag
Zag
Lev
el 1
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 21
• FR11: Control the temperature of the
freezer in the range - 18 C
• FR12:Maintain uniform temperature at
preset temperature
• FR13: Control humidity to relative
humidity 50%
• DP11: Turn on and off the compressor
when the air temperature is higher
and lower that the set temperature
• DP12: Blow the air into the freezer
section and circulate it uniformly
throughout the freezer section at all
times
• DP13: Condense the moisture in the
returned air when its dew point is
exceeded
Zig
Zig
Zig
Lev
el 2
Coupling Could Happens Across Design Hierarchy
VECTOR Design Hierarchy Using Axiomatic Design
Zigzagging Process
.
.
.
Deliverables
.
.
.
Major Activities
Zigg mapping
VECTOR Design process is a mapping from What to How Domains
Zig-zagging
What How
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 22
What How
Zigg mapping Zigzagging is a team activity
Sub-Deliverables Tasks/Activities
Coupling Could Happens Across Design Hierarchy
VECTOR Detail Design Steps
• Two major steps:
1. Zigzag VECTOR � Design mapping
1. Deliverables are mapped to major activities (Level 1 hierarchy)
and Sub-deliverables to tasks (Level 2 hierarchy)
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 23
2. Convert matrices to process maps
1. Find the sequence of activities that minimizes coupling and
thus scrap and rework
2. Sequence activities according to the matrix intended mapping
(black X )
Block 1: Level 1 Zigzagging
No. DPB1-2 DPB1-8 DPB1-1
DPB1-
5,DPB1-
6,DPB1-
7, DPB1-9
Est
ab
lish
In
teg
rate
d D
ata
En
vir
on
me
nt
(ID
E)
Ga
the
r &
Pro
cess
VO
C,
ide
nti
fy c
riti
cal
cust
om
er
ne
ed
s
Design Matrix: Level 1
[A]Relationship Meaning
X A required relationship
exist
X A coupling relationship
exist
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 24
No. Deliverables Major Activities
De
ve
lop
ov
era
ll,
inte
gra
ted
pro
ject
pla
n
Est
ab
lish
In
teg
rate
d D
ata
En
vir
on
me
nt
(ID
E)
Ga
the
r &
Pro
cess
VO
C,
ide
nti
fy c
riti
cal
cust
om
er
ne
ed
s
(Cu
sto
me
r C
en
tric
Pro
cess
)
Co
nta
rct
Aw
ard
ing
Pro
cess
FRB1-1 Project Plan X X X
FRB1-2 Major program assumptions X X X
FRB1-3 Ranked & Prioritized Critical Customer Needs X
FRB1-4 Awarded Contract(s) X
0 No relationship exist
Coupling
Problems With Coupled Design
• Coupling in VECTOR � Reworked and/or
scrapped activities and tasks… NOT Lean
• Inherently a “weak” design because of conflicting
requirements due to the selection or the design of VECTOR
procedures and processes.
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 25
procedures and processes.
• Optimization is at best a trade-off…
• IPT skills, experience and decision making may create
variation in implementation which will aggravates the
complexity of VECTOR.
Select/design/change Vector procedures to Uncouple/ Decouple Design
Design Precedence…
• The sequence of activities revealed by the design matrix will be developed by SSPI similar to the one below
DPB1-2: Contract
DPB1-1 : Gather & Process
VOC, identify critical
FR1: Awarded Contract(s)FR2: Ranked & Prioritized Critical Customer Needs No. DPB1-2 DPB1-8 DPB1-1
DPB1-
5,DPB1-
6,DPB1-
7, DPB1-9
No. Deliverables Major Activities
De
ve
lop
ov
era
ll,
inte
gra
ted
pro
ject
pla
n
Est
ab
lish
In
teg
rate
d D
ata
En
vir
on
me
nt
(ID
E)
Ga
the
r &
Pro
cess
VO
C,
ide
nti
fy c
riti
cal
cust
om
er
ne
ed
s
Design Matrix: Level 1
[A]Relationship Meaning
X A required relationship
exist
X A coupling relationship
exist
0 No relationship exist
DPB1-8: Establish
FR3: Major program assumptions
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 26
DPB1-2: Contract
Awarding Process
VOC, identify critical
customer needs (Customer
Centric Process)
Level 1 Level 1 Level 1 Level 1
MapMapMapMap
No. Deliverables Major Activities
De
ve
lop
ov
era
ll,
inte
gra
ted
pro
ject
pla
n
Est
ab
lish
In
teg
rate
d D
ata
En
vir
on
me
nt
(ID
E)
Ga
the
r &
Pro
cess
VO
C,
ide
nti
fy c
riti
cal
cust
om
er
ne
ed
s
(Cu
sto
me
r C
en
tric
Pro
cess
)
Co
nta
rct
Aw
ard
ing
Pro
cess
FRB1-1 Project Plan X X X
FRB1-2 Major program assumptions X X X
FRB1-3 Ranked & Prioritized Critical Customer Needs X
FRB1-4 Awarded Contract(s) X
DPB1-8: Establish
Integrated Data
Environment (IDE)
DPB1-2: Develop overall,
integrated project plan
FR4: Project Plan
Apply Sequencing Algorithms ( EXCEL/Matlab macros)
Level 2
DPB1-4
DPB1-2 DPB1-2-1 DPB1-2-2 DPB1-2-3 DPB1-2-4
Ide
nti
fy s
kil
ls f
or
pro
ject
an
d f
orm
IP
T (
10
1)
CS
P P
roce
du
re
Pro
ject
Ch
art
er
AR
DE
C M
S P
roje
ct
Re
spo
nsi
bil
ity
[A]
.
.
.
Deliverables
.
.
.
Major Activities
Zigg mapping
What How
Zigg mapping
Zig-
zagging
What How
Sub-Deliverables Tasks/Activities
Develop overall,
integrated project plan
FR4: Project Plan
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 27
Develop overall, integrated project plan Ide
nti
fy s
kil
ls f
or
pro
ject
an
d f
orm
IP
T (
10
1)
CS
P P
roce
du
re
Pro
ject
Ch
art
er
AR
DE
C M
S P
roje
ct
Te
mp
late
Re
spo
nsi
bil
ity
FRB1-2-1 ID Team Members X � Primary Responsibility
FRB1-2-2 Determine CSP X X � Secondary Responsibility
FRB1-2-3 Define Scope X X X
FRB1-2-4 Determine Precedence X X
SE
DE
Project Mngmnt PM
Logistics
Process Assurance (PA)
QESA
otherR =
Re
spo
nsi
ble
; S
=
can
be
Su
pp
ort
ive
; C
=
ha
s to
be
Co
nsu
lte
d;
I
= h
as
to b
e I
nfo
rme
d.
Coupling
VTB Block 1 w/o Common
DPB1-2: Contract
Awarding Process
DPB1-1 : Gather & Process
VOC, identify critical
customer needs (Customer
Centric Process)
DPB1-8: Establish
Integrated Data
Environment (IDE)
DPB1-2: Develop
overall,
integrated project
plan
FR1: Awarded Contract(s) FR2: Ranked & Prioritized Critical Customer Needs
FR3: Major program assumptions
FR4: Project Plan
.
.
.
Deliverables
.
.
.
Major Activities
Zigg mapping
What How
Zigg mapping
Zig-
zagging
What How
Sub-Deliverables Tasks/Activities
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 28
DPB1-2:-1 Identify skills
For project and form
IPT (101)
FRB1-2-1: ID Team Members
DPB1-2-2 CSP
Procedure)
FRB1-2-2: Determine CSP
DPB1-2-3 Project
Charter
FRB1-2-3: Define Scope
DPB1-2-4 ARDEC MS
Project Template
FRB1-2-4: Determine Precedence
Level 2Level 2Level 2Level 2
MapMapMapMap
VTB Block 1 w/o Common (cont’d)
DPB1-8 DPB1-8-1 DPB1-8-2 DPB1-8-3
Giv
e I
PT
acc
ess
rig
hts
pro
ced
ure
(e
.g.
OC
S)-
(au
tom
ati
c/m
an
ua
l)
Re
spo
nsi
bil
ity
.
.
.
Deliverables
.
.
.
Major Activities
Zigg mapping
What How
Zigg mapping
Zig-
zagging
What How
Sub-Deliverables Tasks/Activities
Establish Integrated
Data Environment
(IDE)
FR3: Major program assumptions
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 29
Establish Integrated Data
Environment (IDE) Giv
e I
PT
acc
ess
rig
hts
On
lin
e t
oo
ls o
r a
pro
ced
ure
(e
.g.
OC
S)-
Au
tom
ati
c /M
an
ua
l
Ve
rsio
n c
on
tro
l
(au
tom
ati
c/m
an
ua
l)
Re
spo
nsi
bil
ity
FRB1-8-1 Access project data X � Primary Responsibility
FRB1-8-2 Share poject data X X � Secondary Responsibility
FRB1-8-3 Control project data X X X
SE
DE
Project Mngmnt PM
Logistics
Process Assurance (PA)
QESA
otherR =
Re
spo
nsi
ble
; S
=
can
be
Su
pp
ort
ive
; C
=
ha
s to
be
Co
nsu
lte
d;
I
Coupling
VTB Block 1 w/o Common (cont’d)
DPB1-8-1: Give IPT
access rights
DPB1-8-2 : Online tools or a
procedure (e.g. OCS)-
Automatic /Manual
DPB1-8-3: Version
control (
automatic/manual)
FRB1-8-1: Access project dataFRB1-8-2: hare project data
FRB1-8-3: Control project dataLevel 2Level 2Level 2Level 2
MapMapMapMap
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 30
DPB1-2: Contract
Awarding Process
DPB1-1 : Gather & Process
VOC, identify critical
customer needs (Customer
Centric Process)
Establish Integrated
Data Environment
(IDE)
Develop overall,
integrated project plan
FR1: Awarded Contract(s) FR2: Ranked & Prioritized Critical Customer Needs
FR3: Major program assumptions
FR4: Project Plan
.
.
.
Deliverables
.
.
.
Major Activities
Zigg mapping
What How
Zigg mapping
Zig-
zagging
What How
Sub-Deliverables Tasks/Activities
VTB Block 1 w/o Common (cont’d)
DPB1-2: Contract
Awarding Process
DPB1-1 : Gather & Process
VOC, identify critical
customer needs (Customer
Centric Process)
FR1: Awarded Contract(s)
FR2: Ranked & Prioritized Critical Customer Needs
FR3: Major
program
assumptions
FRB1-2-1: ID Team Members FRB1-2-2: Determine CSP FRB1-2-3: Define Scope
DPB1-8-1: Give IPT
access rights
DPB1-8-2 : Online tools or a
procedure (e.g. OCS)-
Automatic /Manual
DPB1-8-3: Version
control (
automatic/manual)
FRB1-8-1: Access project dataFRB1-8-2: hare project data
FRB1-8-3: Control project data
Establish Integrated
Data Environment
(IDE)
Confidential © 2005 Six Sigma Professionals, Inc. (SSPI) . All Rights Reserved. 31
FR4: Project PlanDPB1-2:-1 Identify skills for
project and form IPT (101)
FRB1-2-1: ID Team Members
DPB1-2-2 CSP
Procedure)
FRB1-2-2: Determine CSP
DPB1-2-3 Project
Charter
FRB1-2-3: Define Scope
DPB1-2-4 ARDEC MS
Project Template
FRB1-2-4: Determine Precedence
Develop overall,
integrated project plan
Need to put the activities in the right swim lanes
Axiomatic Design Top Down
Synthesized Maps
Level 2
Level 1
Level 1 Map: ProcessLevel 1 Map: ProcessLevel 1 Map: ProcessLevel 1 Map: Process
Process Maps
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Level 3
Level 2 Map: Procedure
Level 3 Map: Task
Process Maps
DPB1-2: Contract Awarding Process
DPB1-1 : Gather & Process VOC, identify
critical customer needs (Customer Centric
Process)
FR1: Awarded Contract(s)
FR2: Ranked & Prioritized Critical Customer Needs
FR3: Major
program
assumptions
FR4: Project PlanDPB1-2:-1 Identify skills for project and form IPT (101)
FRB1-2-1: ID Team Members
DPB1-2-2 CSP Procedure)
FRB1-2-2: Determine CSP
DPB1-2-3 Project Charter
FRB1-2-3: Define Scope
DPB1-2-4 ARDEC MS
Project Template
FRB1-2-4: Determine Precedence
DPB1-8-1: Give IPT access rights
DPB1-8-2 : Online tools or a procedure (e.g.
OCS)-Automatic /Manual
DPB1-8-3: Version control (
automatic/manual)
FRB1-8-1: Access project dataFRB1-8-2: hare project data
FRB1-8-3: Control project data
Develop overall,
integrated project plan
Establish Integrated Data Environment (IDE)
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DPTBC1: Conduct Risk Management (104)
FRTBC1:CSP RequirementsGap Analysis
DPTBC8: Involve customers & suppliers early & often
FRTBC8: CSP Validate development work done in this block/phase
DPTBC5: Conduct Critical Parameter
Management Process
FRTBC5: Updated critical parameter management database
DPTBC2: Update Project Plan; Specific Tasks &Activities for each Phase
must be defined & linked to Deliverables.Includes an integrated MS Project/EPM schedule. (101)
FRTBC2: Next Phase detailed plans & constraints
DPTBC7: Report CSP and Risk variances when breached between gates
FRTBC7: Communicate CSP & Risk Status
DPTBC4: ARDEC IP PROCESS
FRTBC4: DocumentedIntellectual Property Status
DPTBC6: Develop process for problem capture and resolution tracking linked to lessons learned database
FRTBC6: Documented Lessons Learned
DPTBC3: Develop & refine technology opportunities and associated business case
FRTBC3: Input to product portfolio financial business case document
Axiomatic Design Advantages
• Hierarchical mapping process
– Systematic design mapping generator
– Way to deal with complexity (deal with small number of steps at a time)
– Logical precedence relationships are easily discovered
• Building block approach
– Lower level maps replaces higher levels when required
• Quality Check
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• Quality Check
– Missed deliverables
– Missed activities
– Ill-worded deliverables
– Ill-worded activities
– Week relationships between deliverables and activities
• Coupling treatment is readily available …uncoupled/decoupled matrices
– Within a Vector block and across blocks (repetitive procedures)
• Linked nicely to Computer-Aided DFSS (product design)
Computer-Aided DFSS (CA-DFSS)
Res
pons
e +
Sen
sitiv
ityM&S Model
Des
ign
Poi
ntNoise Factors
• Use the “most probable point” instead of random samples for hardware DV
Reliability/Robustness
Reduction of DV Test Sample
Yes
Influence
Control Factors
AD Design Matrix
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• Assess reliability & robustness by incorporating noise (variability)
• Identify parameters contribution to reliability & robustness for design direction
• Identify the critical design parameter combination
• Parameter Design to find optimal control factor setting to desensitize performance without controlling variability
• Tolerance Design to select economical tolerance allocation or to control variability
CA-DFSSAssessment
MeetRequirement?
Robustness
Design Point (Nominal and or Tolerance)
CA-DFSSOptimization
InfluenceFactors
No
SSPI Has a Complete Suite of CA-DFSS Software
References
• El-Haik, B., “Axiomatic Quality & Reliability”, John Wiley & Sons, Inc.,
New York, April, 2005.
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Q’s?
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Overall Design Mapping…
{VOC/CTQs}...
{FRs}...
{DPs}...
{PVs}...
Relate map map
[A] [B][C]
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Customer Domain
Functional Domain
Physical Domain
Process Domain
[C] = [A] * [B]
Diagonal Matrix [ ]Triangular Matrix [ ]Full Matrix [ ]
Diagonal Matrix [ ]Triangular Matrix [ ]Full Matrix [ ] *??? =
Possibilities/Probabilities of Design?
Legend
: Coupled matrix (Upper, lower & diagonal)
: Upper triangular matrix
: Lower triangular matrix
: Diagonal matrix
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[A] \[B][A] \[B]
Probability of an overall uncoupled design is…Probability of an overall decoupled design is…
Probability of an overall coupled design is…
Design is a mapping process…
FRs
FR1
FRs
FR1FR1
PVs
PV1
PV11 PV12
PVs
PV1
PV11 PV12
PV1
PV11 PV12
Process Mapping
FRs
FR1FR1
PVs
PV1
PV11 PV12
PVs
PV1
PV11 PV12
PV1
PV11 PV12
FRs
FR1FR1
PVs
PV1
PV11 PV12
PVs
PV1
PV11 PV12
PV1
PV11 PV12
FRs
FR1FR1
PVs
PV11PV11
PVs
PV11PV11
Customer Mapping Physical Mapping
CAs FRs
FR1
FR11 FR12
DPs
DP1
DP11 DP12 PV11PV11
PV1
PV11 PV12
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FR11FR12
FR1
FR11FR12
FR1
FR11FR12PV11 PV12PV11 PV12PV11 PV12
FR1
FR11FR12
FR1
FR11FR12PV11 PV12PV11 PV12PV11 PV12
FR1
FR11FR12
FR1
FR11FR12PV11 PV12PV11 PV12PV11 PV12
FR1
FR11FR12
FR1
FR11FR12PV11PV11PV11PV11FR11 FR12 DP11 DP12 PV11PV11PV11 PV12
Design is a continuous mapping activity between 4 domains:
CAs����FRs����DPs����PVs
Customer Attributes Domain
Functional Requirements
Domain
Design Parameters Domain
Process Variables Domain
Example
FRsFRs PVsPVsFRs PVsPVsFRs PVsPVsFRs PVsPVsCAs FRs DPs
Frig Manfg. Frig
Preserve Stop bacteria
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Other DPs (concepts) to do FR=“Stop Bacteria” Cold, heat, radiation, salt …
Customer Attributes Domain
Functional Requirements
DomainDesign Parameters Domain
Process Variables Domain
Frig Manfg.
ProcessesFrig
Preserve
beefStop bacteria