the “do more engineering” process · 2018-09-07 · pugh matrix taguchi’s parameter design...
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The “Do More Engineering” ProcessINTEGRATING DFMA INTO THE PRODUCT DEVELOPMENT PROCESS
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Boothroyd Dewhurst, Inc. 2018
Activity
Distribute 100% product development cycle time across the four phases
Typical Product Development Process
DesignValidation & Verification
“Go To Market”Concept
SA/GA
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Boothroyd Dewhurst, Inc. 2018
Source: Plastics Design Forum
The More Things Change …
3
20
27
13
55
22
15
5
0 20 40 60 80 100
ConventionalDesign Process
DFMA DesignProcess
Percentage of Design Time
Concept design Initial design
Design changes Data dissemination
40% Time Savings
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Boothroyd Dewhurst, Inc. 2018
The More Things Change …
Exhibit II Japanese automaker with QFD made fewer changes than U.S. company without QFD Source: Lawrence P. Sullivan, “Quality Function Deployment,” Quality Progress, June 1986, p. 39. © 1986 American Society for Quality Control. Reprinted by permission.
HBR Article by John Hauser and Don Clausing … May 1988
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Boothroyd Dewhurst, Inc. 2018
Source: Ford Motor Company
The More Things Change …
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Boothroyd Dewhurst, Inc. 2018
Fabrycky & Blanchard, 1993
The More Things Change …
66%
80%
100%
Conceptual/PreliminaryDesign
Detail Design/Development Production
ProductUse/Support/Phaseout/Disposal
Ease of Change
Cost Incurred
Knowledge
Life Cycle Costs Committed
(Architecture, Technology, Performance, etc..)
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Boothroyd Dewhurst, Inc. 2018
“Do More Engineering” Product Development Process
Tech Dev.
VOC
Portfolio
Business Decision Architecture
Pipeline Resource Management
Metrics
VOC/QFDDFMAVA/VERobust Design
PFMEADFREarly Supplier Inv.Target Costing
DOEPugh MatrixDFMEA
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Boothroyd Dewhurst, Inc. 2018
Definition Stage10 2
43
Design Implementation Stage
Manufacturing and Operations Implementation Stage
65
7 8
Production Stage
“Do More Engineering” Product Development Process
“Make It Work” “Make It Break”
Design
V & V “Go To Market”
Concept
SA/GA
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Boothroyd Dewhurst, Inc. 2018
“Do More Engineering” Best Practices
◦ Multifunctional PD Teams
◦ VOC & QFD
◦ VAVE & Functional Flow Diagrams
◦ DFMA®/ DF”x”
◦ Competitive Benchmarking
◦ Reusability Assessement
◦ Pugh Matrix
◦ Taguchi’s Parameter Design
◦ Robustness Development Fixtures
◦ Systems Engineering
Phase 1 Best Practices Plus:
◦ Early Customer Involvement
◦ Early Supplier Involvement
◦ Decision & Risk Analysis
◦ Fault Tree Analysis
◦ DFMEA/PFMEA
◦ Critical Parameter Layouts
◦ Manufacturing Process Capabilities Assessment
◦ Target Costing
◦ MRP II
Definition Stage10 2
“Make It Work” “Make It Break”O
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Boothroyd Dewhurst, Inc. 2018
Great Process ≠ Great Outcome◦Lacked diligence in Portfolio Management
◦Too many projects/person
◦“Sunk money” syndrome … lacked diligence in canceling projects
◦“Ugly baby” syndrome … prima donna engineers not open to others’ ideas (especially from manufacturing)
◦Poor accountability
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Boothroyd Dewhurst, Inc. 2018
Ingredients for DFMA® Deployment Success◦Structured product development process … phased objectives, deliverables, & tools (Best Practices)
◦Stakeholders set clear expectations/goals and support “good decisions”
◦Consistent, data-driven decision making processes
◦Clear roles & responsibilities (i.e. RASI)
◦Effective competency development
◦Designated subject matter experts (SME’s) to serve as mentors & consultants
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Boothroyd Dewhurst, Inc. 2018
Ingredients for DFMA® Deployment Success
◦Project portfolio management … project identification, prioritization, funding, and staffing
◦Project staffing for success … 2-3 projects/person
◦Project metrics & tracking: status, no. parts, costs, NRE, capital … predicted vs. actual vs. target
◦Lessons learned collected & shared
◦ Integration with other business processes and practices (i.e. VAVE, FMEA, MRP/ERP, etc.)
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Boothroyd Dewhurst, Inc. 2018
Facts … Discipline … Constancy of Purpose
“Without discipline, there is no Marine Corp.”
“In God we trust, all others bring data.”“Create constancy of purpose toward improvement …”
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Thank You!!!