PRESENTED BY: Navjot Sandhu

The Innovator’s Toolkit- Techniques and tools for optimizing and finalizing

designs

Agenda

Objectives Process Capability Predict the performance of your new solution Robust Design Make your design insensitive to uncontrollable influences Design Scorecards Develop a dashboard to track your design and its

underlying processes Discrete Event Simulation Visualize and test your innovation through computer

modeling

Agenda

Rapid Prototyping Make a fast 3D model of your solution to

explore its viability

Managerial challenge

Streamlining a products creation process to meet upper management demands, customer demands, and engineering guidelines

Create an infrastructure so products can be designed and tested quickly using repeatable processes and tools

Objective

Use tools to produce a design into a workable model that can be tested, while tracking changes and progress

Agenda

Objectives Process Capability Predict the performance of your new solution Robust Design Make your design insensitive to uncontrollable influences Design Scorecards Develop a dashboard to track your design and its

underlying processes Discrete Event Simulation Visualize and test your innovation through computer

modeling

Process capability

Engineers need to compare how well a design meets it’s performance expectations.

In the realm of innovation, we want to focus on predictive use.

Helps improve designs

Process capability - Steps

1. Determine specifications• Come from customers, engineering

calculations, or pre-evaluation• Make sure specifications are clear and

unbiased

2.Collect Appropriate Data• Quantitative data – Can be either short or long

term (variable data or numbers)• Qualitative data- yes/no, a particular color

Process capabilities - steps

3.Calculate Capability Metrics• Measure for central tendency’s• Helps to determine where the

specifications of a product should lie

4.Improve the Design or Process• Make it more robust to input variation • Tighten tolerances of specifications and its

related processes for better performance

Process capabilities Moment of truth Discussion Examples Bank is testing a new a kiosk for that provides

customers with rapid approvals on refinancing mortgages

• Measure customer reactions between request/information received – determined information should be displayed within 2 minutes. They expect .6 percent of customers to have wait time more than 2 minutes. If pressured with competition, they can redesign the kiosk to provide more information such as credit score, dollar amount of loan, etc…

Agenda

Objectives Process Capability Predict the performance of your new solution Robust Design Make your design insensitive to uncontrollable

influences Design Scorecards Develop a dashboard to track your design and its underlying

processes Discrete Event Simulation Visualize and test your innovation through computer

modeling

Robust design

Helps reduce sensitivity of the innovation to uncontrollable noise variables.

Variation will occur through the lifecycle of the design through normal wear and tear.

Robust design helps predict the undesired behaviors of a design to minimize customer disappointment.

Robust design

In order to do this you need help from an experienced engineer and also have to know about the following techniques:

Performance and Perception Expectations Axiomatic Design

Matrices of customers needs.

Design FMEA (Design Failure Mode and Effects Analysis) Measurement of potential design errors

Design of Experiments Design of all information gathering exercises where

variation is present

Robust design - Steps

1.Identify Customer Expectations

2.Develop Conceptual Design Create a high level design

3.Identify Control Factors and Noise Variables

4.Identify Potential Deterioration Normal wear and tear, component wear down

5.Experiment and Determine Optimum Design

6.Determine Detailed Design Tolerances Determine specifications that the design needs to operate within

Robust Design Moment of Truth Discussion Examples

Agenda

Objectives Process Capability Predict the performance of your new solution Robust Design Make your design insensitive to uncontrollable influences Design Scorecards Develop a dashboard to track your design and its

underlying processes Discrete Event Simulation Visualize and test your innovation through computer

modeling

Design scoreCards

Helps keep track of changes and progress

System Performance – Predicts how the overall design will perform against its expectations

Component Performance-Predicts of the performance of individual key components that affect overall system performance

Process Performance- Predicts the overall quality level of key processes that produce the product or deliver the service.

More robust a scorecard, more likely a problem can be fixed before customer dissatisfaction occurs

Design scorecards - Steps

1. Identify the Critical Parameters of the Performance Score Card Identify all relevant customer expectations for

your design For each expectations, identify the :

i) type of variable(discrete, continuous) ii)measurement unit

Continous indicators are tracked by their mean and standard deviations

Discrete indicators are tracked by looking at their success rate

Design Scorecards - steps

2. Determine Target and Specifications Limits on Performance Parameters Obtained from customer input, regulatory

requirements, or design functional requirements

Three scenarios apply: i) more is better ii) less is better iii)achieve a specific target

Design scorecards- steps

3. Predict the Performance Indicators Predict what values the indicators should be,

then these will be later compared to actual values

4. Build the Overall and Individual Component Scorecards Identify the critical components that significantly

influence the overall system performance. Identify their critical inputs ( weight, mass, area,

etc..)

Design scorecard - steps

5. Build the Overall and Individual Process Scorecards Identify the critical manufacturing and/or service

delivery processes and sub-processes Build a score card for each critical process

6. Interpret the Scorecard Analyze the scorecards after there is enough data on

them Determine how much and what components and

processes effect the overall performance the most Consider what improvements can be made and where

Overall system performance score card

Overall Component scorecard

Component scorecard

Overall process scorecard

Process scorecard

Design scorecardsmoment of truth

Discussion Examples

Agenda

Objectives Process Capability Predict the performance of your new solution Robust Design Make your design insensitive to uncontrollable influences Design Scorecards Develop a dashboard to track your design and its

underlying processes Discrete Event Simulation Visualize and test your innovation through computer

modeling

Discrete event simulation

Computer based modeling approach that allows the simulation of scenarios

Saves time and money

Has to be done correctly in order to model real world situations accurately

Discrete event simulation- steps

Choose software AutoMod, SigmaFlow, ProcessModel, Arena, iGrafx Vary in cost and features

Develop process flow Create process maps Include sub-processes, decision points, and

queues

Assign process attributes For each process step, enter associated attributes

which could affect the process flow or outcome

Discrete event simulation - steps

Determine resources and attributes Determine the resources of the processes and

sub-processesDetermine process entities and attributes

Determine the entities and their associated attributes that will be a part of the processes

Run trial simulations Look for deficiencies in logic

Discrete event simulations - steps

Run actual simulations Run simulations while varying attributes and

values

Verify results Build a prototype to verify design

Discrete event simulationmoment of truth Discussion Examples

Agenda

Rapid Prototyping Make a fast 3D model of your solution to

explore its viability

Rapid prototyping

Creates a 3-dimensional model of a new innovation or product design

Use this when design needs to be assessed by designers and manufacturing engineers

Need the following CAD Rapid Prototyping Machine

Rapid prototyping

Three techniques availableFormative

Turn raw material into the desired shapeSubtractive

Start with a large solid, then remove material to obtain desired shape

Additive Layer material over and over until desired

shape and position is acheived

Rapid Prototyping - steps

Input CAD data Create a computer design with the correct dimensions

and attributes of your prototype Export Data into Stereolithography Files

Export CAD file into an .stl file Select Material and Specify Process

Depending on machine, we need to select the material Thermoplastic resins, polycarbonate, wax, powdered

materials, plastics, metals Stereolithography technique-stacks horizontal slices

on top of one another

Rapid Prototyping

Create Rapid PrototypeClean and Finish the Prototype

Rapid prototyping

Discussion Examples

Lessons Learned

Turning a design into a product requires patience, know how, experts, and expertise

There are tools available that help cut costs, streamline processes, analyze designs, and allow for organized documentation of details

Most great products need to be designed, tested, and then redesigned

Thanks