Matakuliah
Tahun
: Perancangan Manajemen Mutu
: 2009
Quality in Product and Process Design
Pertemuan 13-14
Chapter 7:
Quality in Product and Process Design
Reference:
S. Thomas Foster, “Managing Quality: An Integrative
Approach”, Second Edition, Pearson Prentice Hall, New
Jersey, 2003
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Quality in Product and Process Design
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Designing Product for Quality
Quality Fuction Deployment (QFM)
Technology in Design
Prototyping Methodologies
Design for Reliability
Environmental Consideration in Design
Discussion and Questions
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Designing Product for Quality
• In design product we must first many Questions
• What does it mean to design products for Quality
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Project Development Process
• Product idea generation
• Customer future needs projection
• Technology selection for product
• Technology development for process selection
• Final product definition
• Product market and distributioaration
• Product design and evaluation
• Manufacturing system design
• Product manufacture, delivery and use
(See Figure 7-1, Project Development Process)
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Quality Fuction Deployment (QFM)
• See Figure 7-2, QFD Layout: The House of Quality:
– Technical Requirements
– Customer Requirements
– Competitive Assigment
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The Steps in Performing a QFD
• Develop a list customer requirement
• Develop a list of technical design elements along the
roof of the house
• Demonstrate the relationships between the customer
requirements and technical design elements.
• Perform a competitive assessment of the customer
requirements
• Prioritize customer requirements
• Prioritize technical requirements
• Final evaluation
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Technology in Design
• Computer Aided Design (CAD) system
– Multiuser CAD Systems
– Geometric Modeling
– Engineering Analysis
– Design Review
– Interface Checking
– Group Technology
• Computer Aided Inspection (CAI)
• Computer Aided Testing (CAT)
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Prototyping Methodologies
• Organizing the Design Team
• The Product Life Cycle
• Product Families and the Product Life Cycle (See Figure
7-13, Cumulatives Product Family Life Cycle)
• Complementary Products
• Design for Manufacture (DFM)
• Design for Maintenability
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Design for Reliability
• Failure Modes and Effects Analysis (FMEA)
– Improvement of the safety, quality, and the realibility
of product
– Improvement of a company’s image and its
competitiveness
– Increased satisfaction from user standpoint
– Reduction in product development cost
– Record of actions taken to reduce a product risk
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FMEA Steps
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Assign each component an identifier
List functions for each part
List one or two failure modes for each fuction
Describe effects of each failure mode
Determine hazards likelihood and catagorieze
Estimate likelihood of failure
Estimate failure detection
Identify hightest risk
Elimanate or reduce highest risk
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Design for Reliability
• Reliability Analysis Tools
– Failure Modes and Effects Analysis (FMEA)
– Fault Tree Analysis
– Failure Modes, Effects, and Criticality Analysis (FMECA)
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Design for Reliability
• Failure Modes and Effects Analysis (FMEA)
– Method for systematically considering each component of a system,
identifying, analyzing, and documenting the possible failure modes
within a system and the effect of each failure on the system.
• Benefits of FMEA
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Improvement of product safety, quality, and reliability.
Improvement of a company’s image and competitiveness.
Increased satisfaction from a user standpoint.
Reduction in product development cost.
Record of action taken to reduce a product risk.
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Design for Reliability
• Basic areas where FMEA can be applied
– Concept: FMEA is used to analyze a system or its subsystems in the
conception of the design.
– Process: FMEA is applied to analyze the assembly and manufacturing
processes.
– Design: FMEA is used for analysis of products before mass production of
the product begins.
– Service: FMEA is used to test industry processes for failure prior to their
release to customers.
– Equipment: FMEA can be used to analyze equipment before the final
purchase.
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Design for Reliability
FMEA Steps
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Figure 7.18
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Design for Reliability
• Fault Tree Analysis
– An analytical tool that graphically renders the combinations of faults that
lead to the failure of the system.
– This technique is useful for describing and assessing the events within a
system.
• Primary Symbols of Fault Tree Analysis
– Events
– Gates
• Gates
– Link the faults to the undesired events within the diagram. Gates show
how faults are related.
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Design for Reliability
• Types of Events (in Fault Tree Analysis)
– Basic events are initiating faults that do not require events below them to
show how they occurred. The symbol used for a basic event is a circle.
– An intermediate event is the result of a combination of faults, some of
which may be primary events.
– This intermediate event is located in the middle of a fault tree. These
events are described by rectangles.
– An expanded event requires a separate fault tree because of its
complexity. For this new fault tree, the expanded event is the undesired
event and would be located at the top of the fault tree.
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Design for Reliability
Figure 7.20
Fault Tree Diagram
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Design for Reliability
• Steps in Fault Tree Analysis
– Become familiar with the system.
– Define the undesired events of the system with the related
contributing and initiating events.
– Develop fault trees for the undesired events.
– Obtain probabilities for the events on the fault trees.
– Evaluate fault trees.
– Analyze the results and proposals for system improvement.
– Change the fault trees to reflect proposed improvements and
renewed fault tree evaluation.
– Perform a worst case analysis.
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Design for Reliability
• Failure Mode, Effect, and Criticality Analysis (FMECA)
– An extensive, but simple method for identifying ways in which an
engineered system could fail.
• Criticality
– In FMECA is important because it prioritizes how the design team should
be spending its resources.
– In general, criticality refers to how often a failure will occur, how easy it is
to diagnose, and whether it can be fixed.
– Critically assessment is somewhat subjective because it depends on the
viewpoint of a service or field analysis.
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Design for Reliability
• Product Traceability
– The ability to trace a component part of a product back to its original
manufacturer.
• Consumer Product Safety Commission (CPSC)
– An independent federal regulatory agency that helps keep American
families safe by reducing the risk of injury or death from consumer
products.
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Environmental Conditions in Design
• Importance
– Currently, society demands much more from product designers than just
high-quality products. Many manufacturers have turned to a more
environmental form of manufacturing that offers positive returns on
investment.
• Green Manufacturing
– Movement that began in Germany with requirements for importers to
remove packaging materials.
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Environmental Conditions in Design
• Design for Reuse
– Designing products so they can be used in later
generations of products.
• Design for Disassembly
– A method for developing products so that they can
easily be taken apart.
• Design for Remanufacture
– A method for developing products so that they parts
can be used in other products. Associated with green
manufacturing.
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Discussion and Questions
• Case 7-1:
– Designing the Ford Taurus: Why Quality Had to be Job 1
• Case 7-2:
– Nucor Corporation: Producing Quality Steel by Stressing Sound
Management Practices
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