POLITECNICO DI TORINO - ITALY DIGEP – Department of Management and Production Engineering 7TH GALILEE QUALITY CONFERENCE, “QUALITY – THEORY AND PRACTICE” ORT BRAUDE COLLEGE OF ENGINEERING IN KARMIEL MAY 1ST 2014 Fiorenzo Franceschini Maurizio Galetto “QFD is a method to transform user demands into design quality, to deploy the functions forming quality, and to deploy methods for achieving the design quality into subsystems and component parts, and ultimately to specific elements of the manufacturing process”. Akao (1988) 2 I like … I like … I want … I wa I want … I like . I want … I want … I want … I like … NEW PRODUCT CUSTOMERS COMPANY 3 QFD PLANNING STRUCTURE Phase IV Phase III Phase II Phase I PROCESS PLANNING MATRIX PART / SUBSYSTEM DEPLOYMENT MATRIX PRODUCT PLANNING MATRIX Customer Customer Requirements requirements PROCESS / QUALITY CONTROL MATRIX Critical Engineering Product Characteristics Requirement Critical Components Characteristics Critical Process Step Process & Quality Control Parameters Critical Process Steps Critical Components Characteristics Critical Engineering Product Characteristics Requirement 4 2. Prioritization of Customer Requirements 1. Customer Requirements 6. Relationship Matrix 4. Competitive Prioritization of Customer Requirements 3. Competitive Benchmarking 7. Correlation Matrix 5. Engineering Characteristics 8. Prioritization of Engineering Characteristics 5 • • • • • Easy to hold Does not smear Point lasts Does not roll … 6 Customer Requirements Engineering Characteristics f QFD work group L • • • • hexagonality, erasure residue, dust, … 7 Customer Requirements (CRs) Easy to hold Does not smear Point lasts Does not roll Engineering Characteristics (ECs) • • • • • • • • • • • length hexagonality time between sharpening lead dust generated erasure residue length time between sharpening lead dust generated erasure residue length hexagonality 8 Does not smear Point lasts Does not roll Erasure residue Hexagonality O Lead dust generated Easy to hold Time between sharpening Customer Requirements (WHATS) Length Engineering Characteristics (HOWS) X O X X O X X X -> weak relationship O -> medium relationship X -> strong relationship 9 • CRs prioritization (are all CRs equally important?) • ECs prioritization. 10 Easy to hold 3rd Does not smear 2nd Point lasts 1st Does not roll 3rd O Erasure residue Hexagonality Lead dust generated Time between sharpening Length Customer Requirements (WHATS) Priorities of WHATS Engineering Characteristics (HOWS) X O X X O X X X Priorities of HOWS Can CRs prioritization influence ECs prioritization? 11 Steps: 1. assign a numerical importance to each CR; 2. convert the relationships symbols between CRs and ECs into “equivalent” numeric values; 3. determine the numerical importance of each EC using the ISM algorithm. 12 Does not smear 3 Point lasts 5 Does not roll 2 1 2 3 4 5 -> -> -> -> -> not important at all minor importance some importance strong importance very strong importance Erasure residue O Hexagonality 2 Lead dust generated Length Easy to hold Customer Requirements (WHATS) Time between sharpening Importance of WHATS Engineering Characteristics (HOWS) X O X X O X X X 13 Importance of WHATS Length Time between sharpening Lead dust generated Hexagonality Erasure residue Engineering Characteristics (HOWS) Easy to hold 2 3 0 0 9 0 Does not smear 3 0 3 9 0 9 Point lasts 5 1 3 9 0 9 Does not roll 2 1 0 0 9 0 Customer Requirements (WHATS) empty box -> 0 -> 1 O -> 3 X -> 9 14 Importance of WHATS Length Time between sharpening Lead dust generated Hexagonality Erasure residue Engineering Characteristics (HOWS) Easy to hold 2 3 0 0 9 0 Does not smear 3 0 3 9 0 9 Point lasts 5 1 3 9 0 9 Does not roll 2 1 0 0 9 0 13 24 72 36 72 Customer Requirements (WHATS) Priorities of HOWS w1 2 3 3 0 5 1 2 1 13 w2 2 0 3 3 5 3 2 0 24 w2 ... n w j di ri , j i 1 15 • • • • • • Intuitional. Easy to use. Easy to interpret. Use of standard Mathematical operators. Largely diffused. … 16 • Are customers really able to express CRs importance on ratio scales (cardinal properties)? • What is the correct symbol codification in the relationship matrix (1-2-3, 1-3-5, 1-3-9, …)? • How to select the right scale for importance and symbol codification? • Is there any arbitrariness in scale definition (zero point, graduation, unit, …)? 17 All CRs have the same importance d = 1. EC1 EC2 EC1 EC2 CR1 X X CR1 X X CR2 X CR2 X CR3 O X CR3 O X CR4 O CR4 O CR5 O CR5 O CR6 O CR6 O Importance 18 Importance 22 15 Codification 1-3-5 Codification 1-3-9 EC1 > EC2 EC1 < EC2 27 18 • The response scale has ordinal properties: Scale level 1 2 Description Not important at all Minor importance 3 4 5 Some importance Strong importance Very strong importance • Arbitrary promotion of results from ordinal to interval or ratio scales. 19 3 1 2 3 4 5 2 1 2 3 4 5 5 1 23 4 5 Can we sentence that the mean value of the 3 2 5 10 sample is x ? 3 3 20 CRs CR1 CR2 1 2 X 3 4 5 X CR3 X We can sentence: • CR1 is better than CR2 We cannot sentence: • CR1 is evaluated twice CR2 (ratio scale) • the distance between CR3 and CR1 is 3 scale units (interval scale). 21 • Respondents’ orderings: 1) CR3 > CR1 > CR2 2) CR1 > CR2 > CR3 3) ... • How operate a fusion of respondents’ orderings? 22 2. Prioritization of Customer Requirements 1. Customer Requirements 6. Relationship Matrix 4. Competitive Prioritization of Customer Requirements 3. Competitive Benchmarking 7. Correlation Matrix 5. Engineering Characteristics 8. Prioritization of Engineering Characteristics 23 • In the scientific literature there are many approaches for prioritizing CRs. • Some of them may lead to misleading results. • In some cases we assist to a violation of scale properties on which CRs are evaluated. 24 • The AHP is a technique of Multiple Criteria Decision Making developed by Thomas L. Saaty (1980). • It is based on the paired comparison of CRs. • The result is a global ordering of the CRs. 25 PAIRED COMPARISON MATRIX a12 1 1/ a 1 12 A ... ... 1/ a1n 1/ a2n ... a1n ... a2n ... ... ... 1 d1 / d1 d / d 2 1 dn / d1 d1 / d2 d2 / d2 dn / d2 d1 / dn d2 / dn dn / dn A d max d d1 d dn PRIORITY VECTOR 26 CR1 (Easy to hold) CR2 (Does not smear) CR3 (Point lasts) CR4 (Does not roll) CRs Importance 1 5 6 7 0.61 CR2 (Does not smear) 1/5 1 4 6 0.24 CR3 (Point lasts) 1/6 1/4 1 4 0.10 CR4 (Does not roll) 1/7 1/6 1/4 1 0.05 CR1 (Easy to hold) 27 • Not always the consistency of paired comparisons is guaranteed. • Respondents usually do not have a common reference scale. • It is based on the assumption that Saaty’s scale for paired comparison has ratio scale properties. • It is “effective” only with small numbers of CRs. 28 • It may lead to inconsistencies in judgment. Example: If CR1 > CR2 and CR2 > CR3 , it can happen for some individuals that CR3 > CR1 . 29 2. Prioritization of Customer Requirements 1. Customer Requirements 6. Relationship Matrix 4. Competitive Prioritization of Customer Requirements 3. Competitive Benchmarking 7. Correlation Matrix 5. Engineering Characteristics 8. Prioritization of Engineering Characteristics 30 The scientific literature proposes many techniques which differ for: • typology of data, • properties of data and scales, • mathematical models for synthesis/aggregation of the information collected from the customers (mean, median, standard deviation, …), • models linking CRs and ECs in the relationship matrix (linear, weighted, …). 31 • Independent Scoring Method (ISM) [Akao, 1988], • Multiple Criteria Decision Aid (MCDA) methods (Electre II, …) [Roy, 1991]. • Interactive Design Requirement Ranking (IDRR) algorithm [Franceschini, 2002]. • Paired Comparison Method (PC) [Thurstone, 1927]. • Ordinal Prioritization Method (OPM) [Franceschini, 2014]. • ... 32 Independent Scoring Method (ISM) Ordinal Prioritization Method (OPM) Multiple Criteria Decision Aid (MCDA) Interactive Design Requirement Ranking (IDRR) Paired Comparison Method (PC) 33 Coefficients of Relationship matrix CRs importance cardinal scale ordinal scale cardinal scale Independent Scoring Method (ISM) Thurstone scaling + Independent Scoring Method (ISM) ordinal scale Thurstone scaling Multiple Criteria + Decision Aid Multiple Criteria (MCDA) methods Decision Aid (MCDA) methods ordering Ordered Weighted Averaging (OWA) ordering Ordinal Prioritization Method (OPM) 34 • It is a variant of Yager’s algorithm (2001). • Each EC is evaluated according to any CR, a preference vector corresponding to each CR can be defined. • There are 3 fundamental phases: 1. Construction and reorganization of decision-makers’ preference vectors. 2. Definition of the reading sequence. 3. Generation of the fused ordering. 35 Reorganized vectors for the pencil example (CR3 > CR2 > CR1 CR4) CR3 CR2 CR1CR4 {EC3,EC5} {EC2} {EC1} {EC3,EC5} {EC2} Null {EC4,EC4} {EC1} {EC1} {EC4} {EC1,EC4} {EC2,EC2,EC3,EC3,EC5,EC5} 36 The ordering algorithm Pass Element (I) Cumulative Occurrences (Ok) Residual elements (R) Gradual Ordering EC1 EC2 EC3 EC4 EC5 (Tk = 1) (Tk = 1) 0 - 0 0 0 0 0 {EC1, EC2, EC3, EC4, EC5} - 1 {EC3,EC5} 0 0 1 0 1 {EC1, EC2, EC4} EC3 EC5 2 {EC3,EC5} 0 0 2 0 2 {EC1, EC2, EC4} EC3 EC5 3 {EC4,EC4} 0 0 2 2 2 {EC1, EC2} EC3 EC5 > EC4 4 {EC2} 0 1 2 2 2 {EC1} EC3 EC5 > EC4 > EC2 5 {EC2} 0 2 2 2 2 {EC1} EC3 EC5 > EC4 > EC2 6 {EC1} 1 2 2 2 2 - EC3 EC5 > EC4 > EC2> EC1 7 {EC1} 2 2 2 2 2 - EC3 EC5 > EC4 > EC2> EC1 8 Null 2 2 2 2 2 - EC3 EC5 > EC4 > EC2> EC1 9 {EC1} 3 2 2 2 2 - EC3 EC5 > EC4 > EC2> EC1 10 {EC4} 3 2 2 3 2 - EC3 EC5 > EC4 > EC2> EC1 11 {EC1,EC4} 4 2 2 4 2 - EC3 EC5 > EC4 > EC2> EC1 12 {EC2,EC2,EC3,EC3,EC5,EC5} 4 4 4 4 4 - EC3 EC5 > EC4 > EC2> EC1 FINAL ORDERING 37 • Ordered Weighted Average (OWA) emulator of arithmetic mean was first introduced by Yager (1993). • This operator is typically used with ordinal scales. SAMPLE SIZE LINGUISTIC QUANTIFIER ORDERED ELEMENT OF THE SAMPLE OWA Max MinQ k , bk n k 1 38 Does not smear S3 Point lasts S5 Does not roll S2 S1 S2 S3 S4 S5 -> -> -> -> -> not important at all minor importance some importance strong importance very strong importance Erasure residue O Hexagonality S2 Lead dust generated Length Easy to hold Customer Requirements (WHATS) Time between sharpening Importance of WHATS Engineering Characteristics (HOWS) X O X X O X X X -> weak relationship O -> medium relationship X -> strong relationship 39 • Q k S f k , k 1,2,..., n is the average linguistic quantifier (the weights of the OWA operator), t 1 with f k Int 1 k ; n • S f k is the f(k)-th level of the linguistic scale (for example Sf(k) = S1 if f(k) = 1); • Int(a) is a function which gives the integer closest to a; • t is the number of scale levels; • n is the sample size. 40 • Number of scale levels: t = 5 (S1, S2, S3, S4, S5). • Sample size: n = 10. • Ordered elements: S5, S5, S5, S4, S4 , S3, S3, S3, S2, S1. • The weights are: Q(1) = S1, Q(2) = Q(3) = S2, Q(4) = Q(5) = Q(6) = S3, Q(7) = Q(8) = S4, Q(9) = Q(10) = S5. 41 OWA= Max MinS1 , S5 ,MinS2 , S5 ,MinS2 , S5 ,MinS3 , S4 ,MinS3 , S4 , MinS3 , S3 ,MinS4 , S3 ,MinS4 , S3 ,MinS5 , S2 ,MinS5 , S1 S3 42 Thank you for your attention! … any questions? 43 • Rossetto S., Franceschini F., “Quality and innovation: A conceptual model of their interaction”, Total Quality Management, v. 6 n. 3, 1995, pp. 221-229. • Franceschini F., Rossetto S., “The problem of comparing technical/engineering design requirements”, Research in Engineering Design, v. 7, 1995, pp. 270-278. • Franceschini F., Rossetto S., “Design for Quality: selecting product's technical features”, Quality Engineering, v. 9, n. 4, 1997, pp. 681688. • Franceschini F., Zappulli M., “Product's technical quality profile design based on competition analysis and customer requirements: an application to a real case”, International Journal of Quality and Reliability Management, v. 15, n. 4, 1998, pp. 431-442. 44 • Franceschini F., Rossetto S., “QFD: how to improve its use”, Total Quality Management, v. 9 n. 6, 1998, pp. 491-500. • Franceschini F., Terzago M., “An application of Quality Function Deployment to industrial training courses”, International Journal of Quality and Reliability Management, v. 15, n. 7, 1998, pp. 753-768. • Franceschini F., Rupil A., “Rating scales and prioritization in QFD”, Total Quality Management, v. 16, n. 1, 1999, pp. 85-97. • Franceschini F., Rossetto S., “QFD: an interactive algorithm for the prioritization of product's technical characteristics”, Integrated Manufacturing Systems, v. 13, n. 1, 2002, pp. 69-75. • Franceschini F., Advanced Quality Function Deployment, St. Lucie Press/CRC Press LLC, Boca Raton, FL, 2002. 45 • Franceschini, F., Galetto, M., Varetto, M., “Qualitative ordinal scales: the concept of ordinal range”, Quality Engineering, v. 16, n. 4, 2004, pp. 515-524. • Franceschini, F., Galetto, M., Varetto, M., “Ordered samples control charts for ordinal variables”, Quality and Reliability Engineering International, v. 21, n. 2, 2005, pp. 177-195. • Franceschini, F., Brondino, G., Galetto, M., Vicario, G., “Synthesis maps for multivariate ordinal variables in manufacturing”, International Journal of Production Research, v. 44, n. 20, 2006, pp. 4241-4255. • Franceschini F., Galetto M., Maisano D., Management by Measurement: Designing Key Indicators and Performance Measurements. Springer, Berlin, 2007. 46