MFG 599-3: Designing in Quality: From Customer Requirements through Product Validation
Pat Hammett, PhD (phammett@umich.edu)
On Campus Class Meeting Time: MW 12:00– 1:30 in 165 Chrysler Center
IOE Office: 1777 IOE (tue office hrs only) Office Hrs: TUE 4-5:30 PM (IOE)
Main Office: 405 UMTRI Building*
UMTRI Phone: 734-936-1121 (Voice Mail)
*Note: Available by appointment at UMTRI Office (UMTRI Building: Huron Parkway/ Baxter)
Session
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2
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7
8
9
10
11
12
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14
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20
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Topic
Course Introduction – New Product Development
and its Challenges, Embedded DFSS
Identify DFSS Project Opportunities
IDDOV Methodology
Define Customer Requirements: Voice of the
Customer Requirements Gathering
NO CLASS MLK Break
Survey Analysis Methods
Product and Process Functional Requirements:
FAST Diagram (Block Diagram)
Requirements Flow Down and House of Quality I
Design Concept Generation: Innovation and
Creative Thinking Techniques
TRIZ Overview
Design Concept Selection: Pugh Matrix, House of
Quality II
Design Failure Mode and Effects Analysis
(DFMEA)
Design Issue Countermeasures, DFX Analysis,
Axiomatic Design Principles:
In-class Exercise – Designing Toys
Assignment
Student Presentations – In Class
Case I Due
Feb 19
No Class – SPRING BREAK
Design Optimization: Design Transfer Functions
and P-Diagrams
Midterm Exam (in class)
Conventional Design of Experiments
Taguchi Robustness Concepts
Taguchi Design of Experiment
Design Optimization Using Response Surface
Methodology
Design Optimization Using Transfer Functions and
Simulation
Multi-Response Optimization and Desirability
Reliability Testing
System Reliability Allocation
Tolerance Analysis: Statistical Tolerance Models
and Simulation
Tolerance Development and Allocation
Validation: Product Design Verification
(Prototypes, Simulations) / Updating Scorecard
Manufacturing Process Validation
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Ex 1 Due
Ex 2 Due
Ex 3 Due
Ex 4 Due
Ex 5 Due
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Course Summary
FINAL Exam – TBD
Course Web Page:
Case 2 Due
Final Exam
ctools.umich.edu
Lecture Notes:
All lecture notes, homework sets, solutions, and tutorials are available through the course web page.
Course Text Book:
The course lecture notes have been developed from a variety of sources.
TEXTBOOK REFERENCE:
Design for Six Sigma: A Roadmap for Product Development
by Kai Yang, Basem S. EI-Haik -- IBSN: 0-071-412085
Others Reference Books Used in the Course:
Taguchi’s Quality Engineering Handbook
G. Taguchi, S. Chowdhury, and Y. Wu, Wiley-Interscience, ISBN: 0471413348
Axiomatic Quality: Integrating Axiomatic Design with Six Sigma, Reliability, and Quality Engineering
B. El-Haik, Wiley-Interscience, IBSN: 047168273X
Engineering of Creativity: Introduction to TRIZ Methodology of Inventive Problem Solving
S. Savransky, CRC Press, ISBN: 0849322553
Response Surface Methodology: Process and Product Optimization Using Designed Experiments
R. Myers and D. Montgomery; Wiley-Interscience, IBSN: 0471581003
Software: Minitab 14 Software or equivalent and QETools Templates Provided
Useful Web Sites:
Product Development: www.npd-solutions.com/bok.html
Six Sigma:
www.isixsigma.com
Instructor:
qetools.com
Statistics Material: http://davidmlane.com/hyperstat/index.html
Other DFSS Books:
- Design for Six Sigma in Technology and Product Development by C. Creveling, J. Slutsky, D. Antis
- Design for Six Sigma: Launching New Products and Services without Failure by Geoff Tennant
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Course Grading
Assignment
Multiple Choice Exercises (5)
Case Study Reports (2)
Class Participation/Discussion
Board
Exam I
Final Exam
Total
Points
50
90
40
100
120
400
Homework: (all homework must be submitted electronically – see instructions on web page).
Case Study Assignments: Assignments must be emailed using a single report file. Acceptable file submittal
formats: (Adobe PDF or MS Word) – For additional format issues on page lengths and headings: See “Case Study
Report Requirements”.
Case #
#1
#2
Topic
IDD – Design Concept Selection
Design Robustness and Optimization
Points
40
50
Case Study and Exercise Submittal Policies:
 Case Study Assignments should be completed in teams of ~3.
 All assignments submitted electronically must be posted by 11:59 PM of the assigned due date.
 For on-line multiple choice exercises, no late homework submittals will be accepted.
 For case study reports, students may turn in one case study four calendar days after it is due.
 If you turn in an assignment after the late date or have more than one late assignment, the maximum
score possible for that assignment will be 20 points.
 Case studies are considered a critical component of this course and students are expected to complete all
case study reports. Failure to complete a case study will result in an additional loss of 20 points (beyond a
0 for the assignment) AND a lowering of your final grade.
Discussion Board/Participation Score (all student discussion posts must be completed by last day of class):
 Throughout the course, I will post various discussion questions within ctools – See ‘Discussion Tab’.
 For off campus students, I will expect you to respond to at least 4 of these (responses should be 1-2
paragraphs in length). Students may create 1 blog/discussion thread of their own at part of their 4
discussion posts (Blog on a Topic of personal interest). I will evaluate your participation score based on
the quality of your discussion postings (Note: you are also welcome to add to in-class discussions).
 For on campus students, I will evaluate your participation score based on a combination of attendance,
participation in classroom discussions, and response to at least 2 instructor discussion posts. Students
may create 1 blog/discussion thread of their own at part of their 4 posts (Blog on a Topic of personal
interest).
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Course Description:
As organizations improve their operational quality, they recognize the need to apply more systematic analytical
techniques to design quality into their products and services. This course provides methods and analysis tools for
preventing quality and warranty concerns. This course focuses on the Design for Six Sigma Quality methodology:
IDDOV. Using the IDDOV framework, this course examines tools and methods for identifying customer
requirements, evaluating design concepts, and optimizing processes to meet quality objectives. The course
integrates several tools from Voice of the Customer Analysis, Transfer Functions, Failure Mode Effects Analysis,
TRIZ, DFX Analysis, Experimental Design, Taguchi Methods, Response Surface Methodology, Design for
Reliability, and Tolerance Simulation and Analysis.
Course Objectives and Outcomes:
Links shown in brackets are to departmental educational objectives:
COURSE
OBJECTIVES
1 Know how to apply basic statistical procedures to solve engineering problems.
2 Build a base of skills in drawing conclusions from data using modern statistical
software
3 Learn how to gather design requirements and build quality into a product or service.
4 Integrate statistical analysis tools with quality problem solving methodologies.
Links shown in brackets are to course objectives:
COURSE
OUTCOMES
1 Appreciate the challenges with gathering customer requirements and developing
new products and services.
2. Learn innovation and design analysis techniques to create products that better meet
customer requirements.
3. Know graphical and numerical techniques for summarizing and presenting data.
4. Know methods for drawing valid conclusions (inference) for different situations
such as tests of hypothesis.
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