phases of design (product lifecycle)singhose.marc.gatech.edu/courses/me2110...
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Phases of Design (Product Lifecycle)1) Customer Requirements
Understand the Problem
2) Specification DevelopmentEngineering Requirements
3) Conceptual Design4) Detail Design5) Specification of Production6) Manufacture7) Recycle
GeneralHouse of Quality
CustomersRequirements
DesignRequirements
Relating Customer Needs and Design
(Problem Understanding Form, Relationship Matrix)
Need #1
Need #2
...
Req #1
Req #2
9
3 1
What (Market / Need) How (Manufacture) Relationships Conflicts
– Customer– Producer
Competition
Using the House of Quality
Analyzing and Diagnosing the Problem
Blank rows & columns Conflicts in the customer vs. technical survey. Sales Points Resolve Negative Correlations Final Targets Correct What design requirements to be deployed to Phase
II (Parts Deployment)?
Look for
4 Phases of QFD(Car Door Example)
Product planning– Close door easily– Close fit
Part deployment– Weather strip– Latch
Process planning (W. Strip)– Extrude
Production planning– Temperature– Pressure– Speed
Steps in QFD What How How Much Relationship Matrix Correlation Matrix Competitive Analysis Analyze Deploy
Remember QFD
–is a planning tool–is one of many planning tools
Charts–are the means–are not the ends
Phases of Design (Product Lifecycle)1) Customer Requirements
Understand the Problem
2) Specification DevelopmentEngineering Requirements
3) Conceptual Design4) Detail Design5) Specification of Production6) Manufacture7) Recycle
Functions & Sub-Functions
Function
SF1 SF2 SF3
SF11 SF12 SF13 SF21 SF22 SF23 SF31 SF32 SF33
(Function Tree)
Moving SeatFunctions & Sub-Functions
Increase Safety
Be Comfortable Move During Crash Reduce Injuries
MaintainShape
Fit HumanBody
SenseCrash
FollowDesired
Trajectory
Increase BottomAngle
Do not Send Victim
Through Roof
Function Table (List Possible Solutions)
Sub-Function \ Solution
1 2 ... j ... m
1 SF1
S11
S12
S1j
S1m
2 SF2
S21
S22
S2j
S2m
...
i SFi
Si1
Si2
Sij
Sim
...
n SFn
Sn1
Sn2
Snj
Snm
Checklist for Developing aSpecification List (1) Geometry
– Size, height, length, space requirement…
Kinematics– Type of motion, velocity…
Forces– Direction & magnitude of force, frequency, stiffness, stability…
Energy– Output, efficiency, loss, ventilation, heating, cooling, supply,
storage…
Spec List Checklist (2) Material
– Physical and chemical properties, auxiliary material, prescribedmaterials (food regulations, etc.)…
Signals– Inputs and outputs, display, control system…
Safety– Safety principles, protective systems…
Ergonomics– Person-machine relationship, type of operation, cleanliness of
layout, lighting…
Production– Factory limitations, maximum dimensions, preferred production
methods, achievable quality and tolerance…
Spec List Checklist (3) Quality control
– Testing & measuring, special regulations & standards…
Assembly– Special regulations, installation, foundations…
Transport– Limitations of lifting gear, clearance, means of transport …
Operation– Sound level, wear, special uses, destination (hot, cold, salty)…
Spec List Checklist (4)
Maintenance– Service intervals, inspection, exchange & repair, painting,
cleaning…
Recycling– Reuse, reprocessing, waste disposal, storage…
Costs– Maximum manufacturing costs, cost of tooling, investment and
depreciation…
Schedules– End date of development, project planning, delivery date…
Example: A Pencil Task: Design A Pencil
– Functions:– Make An Erasable Mark– Erase An Erasable Mark
Constraints– Can Be Made Into A Point– Holds Point– Comfortable To Use– Cheap– Non-Toxic
House Of House Of House Of House Of House OfQuality #1 Quality #1 Quality #2 Quality #3 Quality #4
What How / What (#2) How / What (#3) How / What (#4) How
Cust. Req. Characteristic Feature Process Production
Hot Serving Temp. Water Temp. Water Speed ThermometerSmells Good Smell Jury Bean’s Origin Heater Output Flow ControlTastes Good Taste Jury Water Quality Brew Time TimerCheap Price Weight/Serving Brew Temp. Cleaning PlanGood Color Color Std. Fineness Of
Ground.Grind Setting Disposal Plan
(Raw, Brewed)Non-Poisonous Analysis Age Of Coffee Water SourceNo Grounds Filter/Weigh (Raw, Brewed) Filter Quality
Time To Serving
Reinitialize
(Renew Filter, Grounds)
Entries in Houses of Quality From QFD areSources Of Specifications
Back to Coffee Example
Issued:
Specification
For: CUP OF COFFEE Page 1
Changes D/W Requirements Resp. Source
Cup Of Coffee
EnergyHot
MaterialGood ColorNon-PoisonousNo Grounds
SafetyNon-Poisonous
SignalsGood ColorSmells GoodTastes Good
CostsCheap
Quality ControlGood ColorSmells GoodTastes Good
1st HoQ WHATs fromclass
“““
“
“““
“
“““
Replaces Issue Of
Coffee Specifications #1
Next Level Of Detail In Specs...
House Of House Of House Of House Of House OfQuality #1 Quality #1 Quality #2 Quality #3 Quality #4
What How / What (#2) How / What (#3) How / What (#4) How
Cust. Req. Characteristic Feature Process Production
Hot Serving Temp. Water Temp. Water Speed ThermometerSmells Good Smell Jury Bean’s Origin Heater Output Flow ControlTastes Good Taste Jury Water Quality Brew Time TimerCheap Price Weight/Serving Brew Temp. Cleaning PlanGood Color Color Std. Fineness Of
Ground.Grind Setting Disposal Plan
(Raw, Brewed)Non-Poisonous Analysis Age Of Coffee Water SourceNo Grounds Filter/Weigh (Raw, Brewed) Filter Quality
Time To Serving
Reinitialize
(Renew Filter,Grounds)
Issued:
Specification
for: Cup Of Coffee Page 1
Changes D/W Requirements Resp. Source
10/3/9510/3/95
10/3/95
10/3/95
10/3/95
Cup Of Coffee
Energy:Serving Temperature
Material:Color StdNon-PoisonousBrewed Coffee Should Yield Minimum Coffee
Grounds When FilteredSafety:
Non-PoisonousSignals:
Color StdSmells JuryTaste Jury
Costs:Minimize Price
Quality Control:Color StdSmells JuryTaste Jury
1st HoQ from class
NIST STDFDA1st HoQ from class
FDA
NIST STD1st HoQ from class
“
1st HoQ from class
NIST STD1st HoQ from class
“
Replaces issue of
Coffee Specifications #2: “Hows?”
Coffee Specifications #3: “How Muches?”(Pretty Close to a Spec Sheet - add all the specifics you can)
Issued:
Specification
For: CUP OF COFFEE Page 1
Changes
D/W Requirements Resp. Source
10/4/9510/4/95
10/4/95
10/4/95
10/4/95
Cup Of Coffee
Energy:Serving Temperature, 140
oF
Material:Color Std, NIST # ?Non-Poisonous, < X1, X2, ...mg/lBrewed Coffee Should Yield < Y mg/l Coffee
Grounds When FilteredSafety:
Non-Poisonous, < X1, X2, ...mg/lSignals:
Color Std, NIST # ?Smells Jury, 95% ConsensusTaste Jury, 95% Consensus
Costs:Minimize Price
Quality Control:Color Std, NIST # ?Smells Jury, 95% ConsensusTaste Jury, 95% Consensus
1st Hoq From Class
NIST STDFDA1st HOQ From Class
FDA
NIST STD1st HOQ From Class
“
1st HOQ From Class
NIST STD1st HOQ From Class
“Replaces Issue Of
House Of House Of House Of House Of House OfQuality #1 Quality #1 Quality #2 Quality #3 Quality #4
What How / What (#2) How / What (#3) How / What (#4) How
Cust. Req. Characteristic Feature Process Production
Hot Serving Temp. Water Temp. Water Speed ThermometerSmells Good Smell Jury Bean’s Origin Heater Output Flow ControlTastes Good Taste Jury Water Quality Brew Time TimerCheap Price Weight/Serving Brew Temp. Cleaning PlanGood Color Color Std. Fineness Of
Ground.Grind Setting Disposal Plan
(Raw, Brewed)Non-Poisonous Analysis Age Of Coffee Water SourceNo Grounds Filter/Weigh (Raw, Brewed) Filter Quality
TIME TOSERVINGREINITIALIZE
(RENEWFILTER, GROUNDS)
Continue with Next Level of Detail in Specs
Design Tools at Your Disposal
1) House of Quality-Subcomponents, Problem Understanding Form, etc.
2) Function Trees3) Function Tables4) Specification Lists
Management & Planning Tools
Affinity Diagram (1) Interrelationship Digraph (2) Tree Diagram (3)
Prioritization Matrices (4)
a b c d
Matrix Diagram (5)
123456
a b c d e f g h
Affinity Diagram Purpose:
– Creative process (generate & organize ideas) Start with:
– What is issue under discussion? Then:
– Brainstorm ideas Then:
– Gather ideas under affinity headings
Affinity Diagram (1)
Affinity Diagram Example Reduce Data Entry Complexity (Selling, Leasing, Tracking Products)
ImprovedTraining
ErrorPrevention
ProblemSolving
ImprovedHardware
OpticalScanningSystem
On-LineSystem at
Customer Site
VoiceActivatedSystem
AutomatedEntry
ImprovePaperwork
Standardizecompletion Format
Increase Size toIncrease Legibility
Train Clerical Salesand Customer
Service Personnel
Shorten 11-DigitProduct Code
Color Code Forms byProduct Group
Forms Contain OnlyNon-Standard
Customer information
FriendlySoftware
Inlet
MenuDriven
Outlet
DisplayOnly
CriticalInfo. OnScreen
ImprovePrompts
Interrelationship Digraph Purpose:
– To show causality between items– To identify drivers and bottlenecks– Can be used to fill in roof of house of quality
First:– Write down items to be discussed
Then:– Draw arrows between items– From to indicates causality
Arrows– Most out arrows primary: driver– Most in arrows secondary: bottleneck
Interrelationship Digraph (2)
Interrelationship Digraph Example Repeated service calls on a machine
WrongPerson Sent
RepeatServiceCalls
ProblematicCustomer
Lack of Knowledge ofJob by Subcontractor
Interviewer
Lack of GoodPeople
PoorMatching of
People
Lack of TradesExperience inManagement
Lack of FormalRecord of
What Final Jobis
Lack of Clear JobExpectations bySubcontractor
WrongTools
Lack of Info.on Job
Lack of Knowledge ofMatching People toJob Requirements
UnclearCustomer
ExpectationsAdvertisingPromises
Tree Diagram Purpose:
– Paths and tasks to accomplish primary goal and itsrelated sub-goals
First:– List main what (goal)
Then:– List “Hows” (means)– These become goals (“Whats”) for next level
Continue until you get to assignable tasks
Tree Diagram (3)
Tree Diagram Example Reduce Data Entry Complexity
Clerical
SalesCustomer Service
Reps.
Reduce DataEntry Complexity
ImprovedTraining
ImprovedHardware
FriendlySoftware
ImprovePaperwork
Error Prevention TrainingSeq. Inspection TrainingProblem Solving TrainingOptical Scanning System
On-Line System at CustomerSite
Increase Monitor SizeVoice Actuated System
Menu DrivenImprove Prompt
Auto Check on Standardprice Database
Display Only Non-StandardInformation on Screen
Increase Size for Legibility
Forms Contain only Non-Standard Information
Color Code Form by Product
Shorten Product CodeMore Obvious Difference
Among product Groups CodesTrain Clerical, Sales and
Customer Service Personnel
Automated Entry
Manual Entry
Input
Output
Form
Coding System
StandardizedCompletion Format
Prioritization Matrix
Purpose:– To prioritize items:
Prioritization against themselves Prioritization against criteria
This allows you to focus limited resources
Prioritization Matrices (4)
a b c d
A B C D E
Taste A X - + + +
Smell B + X + + +
Poisonous C - - X + -
Color D - - - X -
Temperature E - - + + X
5.6 0.8 15.2 20 10.4ΣC1 ΣC2 ΣC3 ΣC4 ΣC5
+ = 5, - = 1/5
%ΣR1/ΣC 0.2923 29.23
ΣR2/ΣC 0.3846 38.46
ΣR3/ΣC 0.1077 10.77
ΣR4/ΣC 0.0154 1.54
ΣR5/ΣC 0.2000 20.00
52ΣC
Total 100.00
Prioritization Matrix (Coffee Example)
Matrix Diagram Purpose:
– To show relations between two sets– To show strength of relations
Basic types– QFD– Job responsibilities
Matrix Diagram (5)
123456
a b c d e f g h
⊕ = Primary Responsibility, O = Secondary ResponsibilityD = Needs To Know
Job Responsibilities
Matrix Diagram (Interview Example)
Boss Organizer Staff person
Travel
Pick Date
Schedule
Benefits Discussion
Dinner
Follow-Up
D ⊕ ⊕
O ⊕ D
D ⊕ O
⊕ O D
O D ⊕
⊕ O
Relationship of MP Tools to QFD
(1)Affinity
Diagram
(3)Tree
DiagramRequirements
Flow
(4)Prioritization
Matrices
(2)Interrelationship’s
Digraph
(How)Product
Characteristics
(5)Matrix
DiagramRelationships
How Much
ImportanceTarget Values
Importance Ratings
Interrelationships
Characteristics
Requirements
(What)Customer
Requirements
Com
petit
ive
Ass
essm
ent
Prio
ritiz
atio
n
Use of M&P Tools for ME2110 Design Project
Affinity Diagram to Organize Ideas for Each Problem (Improve Machine Repeatability,…) Interrelationship Digraphs to Debug Machine (Loss of Power, Premature Triggering,…) Tree Diagrams to Assign Tasks (Buy wood, Build frame, Program controller,…) Prioritization Matrix to Create Task Timeline Matrix Diagram to Ensure You are Addressing All Needs Etc.
Summary Management and planning tools allow you to:
– Plan more formally– Organize information– Deal with qualitative information– Show relations between items and issues
Use Them!!!