Training Presentation on Design
Control
Ryan McLaughlin
OISM 470W
Design Control
What Will Be Covered
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Definition of Design Control
Technology In Design
Taguchi Method
Benchmarking
QS 9000
Summary
Definition of Design Control
Design Control – “A set of steps
focused on managing the design
of a product.”
Brainstorming Exercise
Think of how much money your
organization spends on error
correction each year.
Implementing a Design Control
system can cut long term costs
as well as improve quality and
eliminate waste.
Technology In Design
In today’s changing world,
technologies like Computer
Aided Design (CAD) have
emerged as the standard tool in
designing new products.
Brief Overview of CAD
• Can be used to simulate realworld situations.
• Multi-User CAD systems
• Design Review
• Computer Aided Inspection (CAI)
• Computer Aided Testing (CAT)
Why Implement a CAD
System?
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Reduce costs
Improve Accuracy of Design
Improve Accuracy of Testing
Overall Improvement in Quality
The Taguchi Method
The Taguchi Method for quality
improvement is named after Dr.
Genichi Taguchi who first
introduced the method at AT&T
Bell Laboratories in 1980.
The Taguchi Method
The Taguchi Definition of Quality
• differs from traditional definitions of
quality
• Taguchi said Ideal Quality is
delivered when “a product or service
performs its intended function
throughout its projected life under
reasonable operating conditions
without harmful side effects.”
The Taguchi Method
• Robust Design
products should be designed
so that they are free of all
defects and are of the highest
quality.
Robust Design
(The Taguchi Method)
Three Step Method for Creating
Robust Designs
• Concept Design
• Parameter Design
• Tolerance Design
Concept Design
• Deals with the design of the
process.
• Properly selecting process
components and methods can
reduce costs and increase the
quality of the finished product.
Parameter Design
• Deals with finding the optimal levels
of variables that management can
control in a process.
• Parameter design does not usually
affect production costs, but rather
attempts to find the best level of
performance for the system.
Tolerance Design
• Refers to finding the acceptable
variation limits after the
parameter design has been
established.
• Usually results in an increase in
production costs, but also an
increase in production quality.
Robust Design Steps
In order to create a robust design,
the following steps are used to
incorporate the three
perspectives Taguchi states.
Steps for Creating a
Robust Design
1. Identify
the main
Function
2. Identify
the noise
factors and
testing
conditions
3. Identify the
quality
characteristics
to be observed
and the
objective
function to be
optimized
4. Identify
the control
factors and
their
alternative
levels
5. Design the
matrix
experiment and
define the data
analysis
procedure
6. Conduct
the matrix
experiment
7. Analyze the
data and
determine
near optimum
levels for the
control factors
8. Predict
the
performance
at these
levels
Benchmarking
Another method that can be
helpful in creating high quality
designs is benchmarking.
A benchmark is a company which
is recognized for being the best
in a certain field.
Benchmarking
• Companies model themselves after
the benchmark corporations in their
specific field.
• The initiator firm might contact the
target firm for information and
statistics to be used for improvement
of both corporations.
Benchmarking
There are six types of benchmarking.
• Process Benchmarking
• Financial Benchmarking
• Performance Benchmarking
• Product Benchmarking
• Strategic Benchmarking
• Functional Benchmarking
QS 9000
• QS9000 is a supplier development
program
• Provides a supplier standard for auto
companies
• QS9000 has a requirement dealing
with design control
QS 9000
The Design Control Requirement
of QS9000.
• Suppliers must be qualified in
value engineering, geometric
tolerance and dimensioning, and
the Taguchi Method.
QS9000 – A Real World Example
• A team of representatives from
GM, Ford and Chrysler
developed the QS9000 standard,
including the standard for
design control.
• Suppliers to these auto
manufactures need to be
QS9000 certified.
Exercise
• Write down the approximate annual cost of
error correction and losses due to poor
quality in your organization.
• Now calculate approximately how much a
design control system such as CAD would
cost to implement. A QMS/ISO9000 Design
control system can cost between $10,000
and $500,000, depending on the size of the
corporation.
• Consider that it could be free to employ the
Taguchi Method and also improve quality
and cut costs.
Summary
• Design Controls can help improve
quality and cut costs.
• Free ideas like the Taguchi Method
are harder to implement but can pay
off in the end.
• Technology like CAD systems can
also aid in design quality
Bibliography
• http://mijuno.larc.nasa.gov/pap/robdes/robdes.html
“DESIGN FOR COST AND QUALITY: THE ROBUST DESIGN
APPROACH.” By Resit Unal and Edwin B. Dean
• “Managing Quality, An Integrative Approach” By S.
Thomas Foster
• “Plant and Service Tours in Operations Management” by
Roger W. Schmenner
• http://manufacturing.software-directory.com/software2.cdprod1/014/863.QMS.Programs..ISO.9000.Design.Contr
ol.ISO.9000.44.shtml QMS PROGRAMS /ISO 9000 DESIGN
CONTROL (ISO 9000/4.4)