Quality by DesignQuality by DesignChapter 12Chapter 12

November 2, 2000November 2, 2000

Tami HackettTami Hackett

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Jeri StortzumJeri Stortzum

Quality by DesignQuality by DesignDefinedDefined

The practice of The practice of using a using a multidisciplinary multidisciplinary team to conduct team to conduct conceptual thinking, conceptual thinking, product design, and product design, and production planning production planning all at one time. all at one time.

Quality by Quality by DesignDesign

Quality by DesignQuality by DesignTeamTeam The team is composed The team is composed

of specialists from of specialists from business, engineering, business, engineering, production, and the production, and the customer base. customer base.

Suppliers of process Suppliers of process equipment, purchased equipment, purchased parts, and services are parts, and services are also on the team at also on the team at appropriate times.appropriate times.

Design with out QualityDesign with out Quality

In the past, the major In the past, the major functions within an functions within an organization would organization would complete their task by complete their task by “throwing it over the “throwing it over the wall” to the next wall” to the next department in the department in the sequence without sequence without concern for potential concern for potential problems.problems.

Rational for ImplementationRational for Implementation

Lead-TimeLead-Time Fewer Design ChangesFewer Design Changes Lower Reject and Scrap RatesLower Reject and Scrap Rates Reduce Customer ReturnsReduce Customer Returns Reduce ReworkReduce Rework

Rational for ImplementationRational for Implementation

Increased ProfitsIncreased Profits Increased Product PerformanceIncreased Product Performance Increased Market ShareIncreased Market Share Improved Customer SatisfactionImproved Customer Satisfaction

Benefits of Quality by DesignBenefits of Quality by Design

The primary benefit is a significant The primary benefit is a significant decrease in time to the market.decrease in time to the market.

Other benefits: faster product Other benefits: faster product development; better quality; less work in development; better quality; less work in progress; fewer engineering change progress; fewer engineering change orders; increased productivity.orders; increased productivity.

Quality by Design Quality by Design TeamsTeams

Changing “Business as Usual” Changing “Business as Usual” PhilosophyPhilosophy

Top Down CommitmentTop Down Commitment Team CommitmentTeam Commitment

Communication ModelsCommunication Models

Traditional Traditional

Organization StructureOrganization Structure

Quality by DesignQuality by Design

Organization StructureOrganization Structure

Oh my pretty ball, tell this Oh my pretty ball, tell this man which organization man which organization structure is best of all.structure is best of all.

Traditional Organizational Traditional Organizational StructureStructure

M arketing S ales C us tomer

S ervic e

B us iness

M anagement

P roduc t

E ngineering

R esearc h

E ngineering

Quality

E ngineering

E ngineering

M anagement

P lant

E ngineering

M aintenance

E ngineering

P roduc tion

E ngineering

P roduc tion

M anagement

Organization Management

Quality by DesignQuality by DesignOrganization StructureOrganization Structure

OrganizationOrganizationManagementManagement

BusinessBusinessManagementManagement

MarketingMarketing Customer Customer ServiceService

SalesSales

Production Production ManagementManagement

Plant Eng.Plant Eng. Production Production Eng.Eng.

Maintance Maintance Eng.Eng.

Engineering Engineering ManagementManagement

ProductEProductEng.ng.

Quality Quality Eng.Eng.

ResearchEResearchEng.ng.

Implementation of Implementation of Quality by DesignQuality by Design

Look at the Whole Look at the Whole

Product Life CycleProduct Life CycleInternal & ExternalInternal & External

CustomersCustomersCommitment to QualityCommitment to Quality

in the Processin the ProcessOpen CommunicationOpen Communication

Quality by Design Quality by Design ToolsTools

OrganizationalOrganizational

Product DevelopmentProduct Development

ProductionProduction

StatisticalStatistical

Organizational ToolsOrganizational Tools

TQM PhilosophiesTQM Philosophies Computer NetworksComputer Networks ISO 9000ISO 9000 ISO 14000ISO 14000 TPMTPM QFDQFD EDIEDI

Product Development ToolsProduct Development Tools

CADCAD Solid ModelingSolid Modeling FEAFEA Parametic AnalysisParametic Analysis Rapid PrototypeRapid Prototype DFMADFMA FMEAFMEA

Production ToolsProduction Tools

CAMCAM CNCCNC CPICPI JITJIT Virtual ManufacturingVirtual Manufacturing Agile ManufacturingAgile Manufacturing

Statistical ToolsStatistical Tools

DOEDOE

SPCSPC

Quality by DesignQuality by Design

PitfallsPitfalls

MisconceptionsMisconceptions