Chapter 7

Quality and
Innovation in
Product
and Process
Design

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Chapter 7

Designing products for quality

The Design Process
Quality function deployment
(QFD)
Technology in design
Prototyping methodologies
Designing for reliability
Environmental considerations in
design
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing products for quality

What are the functions the

customer wants?
What are the capabilities of the
current product?
What are the limitations of the
material we have selected?
Are there better materials
available?
How much will the product cost to
make?
Copyright How much must the product cost to
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
The Design Process

Product idea generation

Internal and external sources

brainstorm new concepts.

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
The Design Process

Product idea generation

Internal Sources:
Marketing
Management
Research and development
Employee Suggestions

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
The Design Process

Product idea generation

External Sources:
The Customer

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
The Design Process

Technology selection
Technology feasibility statement
Technology development for process
selection
Final product definition
Product marketing and distribution
perpetration
Product design and evaluation
Manufacturing system design
Product manufacture, delivery and
Copyright use
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Quality Function Deployment (QFD)

The House of Quality

A means for implementing customer

needs into functional design

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Quality Function Deployment (QFD)

QFD Step by Step:

1. Develop a list of customer
requirements
2. Develop a listing if technical
design elements
3. Demonstrate the relationship
between the customer
requirements and technical
design elements

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Quality Function Deployment (QFD)

QFD Step by Step:

4. Identify the correlation between

design elements
5. Perform a competitive
assessment of the customer
requirements.

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Quality Function Deployment (QFD)

QFD Step by Step:

6. Prioritize customer requirements
7. Prioritize technical requirements
8. Final Valuation

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

Designers tools:
A square
A pencil
A drafting Table

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

Designers tools:
A square
A pencil
A drafting Table

Replaced by -----

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

CAD
Computer Aided Design

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

CAD
Computer Aided Design
And
Multi-user CAD Systems

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

CAD
Computer Aided Design
And
Multi-user CAD Systems
Hundreds of designers on the system
simultaneously
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

CAD
Geometric Modeling
Engineering analysis
Interface checking

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Technology in Design

CAD/CAM

Computer Aided Design

Computer Aided Manufacturing

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Prototyping Methodologies

Prototyping
An iterative approach to design in
which a series of product mockups
are developed until the costumer
and designer agree on the final
design

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Prototyping Methodologies

Basic Prototype
Non-working mockup of a product

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Prototyping Methodologies

Paper Prototype
A series of drawings developed …
on CAD

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Prototyping Methodologies

Working Prototype
Fully working models of the final
product

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Prototyping Methodologies

 Organizing the Design Team

 Product Life Cycle / Product families
 Complementary products
 Designing products that work
 Design for the manufacturing method
 Design for maintainability

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Failure Modes and Effects Analysis
(FMEA)
1. Improvement of safety, quality and
reliability
2. Improvement of a companies image
3. Increased user satisfaction
4. Reduction in product development cost
5. Record of actions taken
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Where FMEA can be applied
1. Concept
2. Process
3. Design
4. Service
5. Equipment

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 How FMEA works
1. Give each component in the system a
unique qualifier
2. List all functions each part of the system
performs
3. List the one or two failure modes for each
function

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 How FMEA works
4. Describe what effect each failure mode of
the component will have.
5. Determine whether the failure will result in a
hazard
6. Estimate the relative likelihood of
occurrence for each failure in a 10 point
scale
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 How FMEA works
7. Estimate the ease with which the failure
may be detected
8. Use the estimates from steps 5,6 and 7 to
identify the highest risks
9. Decide what action will be taken to eliminate
or reduce the likelihood…

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Fault Tree Analysis

An analytic tool which graphically renders

the combination of faults that lead to the
failure of a system

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Failure Modes, Effects and Criticality
Analysis (FMECA)
1. A description of the products functions
2. Listings of the potential failure modes
3. Potential effects each failure mode could
have
4. Potential causes of each failure mode
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Failure Modes, Effects and Criticality
Analysis (FMECA)
5. Preventive measures
6. Ranking of each preventive measure
7. Ranking of the difficulty of detection
8. An estimate of the probability that a cause
of a potential failure will be detected and
corrected.
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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Designing for Reliability

Reliability Analysis Tools

 Product Traceability and Recall Procedures

Unforeseen defects will occur.

 Product traceability
 Recall procedures
 Trace products with a minimum of cost

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Environmental Considerations in Design

Green Manufacturing

 Design for reuse

 Design for disassembly
 Design for remanufacture

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 Strategic Quality Planning
Quality and Innovation in Product and Process
Design
Summary

As life cycles for products become

shorter a focus on quality is necessary to
remain competitive

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