1 designing products and processes with a future

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Designing Products and Processeswith a Future

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What does it take? Involve the customer

Meet with the customer

Listen to customer

Educate the customer

Incorporate quality function deployment (QFD)

Design for robustness

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What is a customer?

The person who buys the product? The federal regulator? The consumer reporter? The marketing and sales department? Engineering? Manufacturing? Suppliers?

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How do you hear the customer?

Needs Wants Satisfaction Perception

Features

Quality

Value

Importance

Competitors

Detractors

ABOUT

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Product DesignWhat the Customer wanted

What Marketing described

What Engineering designed

Actually Manufactured

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Idea generation Assessment of firm’s ability to carry out Customer Requirements Functional Specification Product Specifications Concept Generation Concept Selection Engineering Design Engineering Evaluation Prototype and Testing

Manufacturing Design

What is Design? ……A Decision Making Process

Flexibility

Cost

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Few SuccessesFew Successes

0

500

1000

1500

2000

Development Stage

Number

Product specification

100

1000

Market requirement

Ideas1750

One success!

Functional specifications

500

Design review,Testing, Introduction

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QUALITY FUNCTION DEPLOYMENT

QFD: An approach that integrates the “voice of the customer” into the product and service development process.

Quality Function DeploymentUses the voice of the customer to build a

design tool:

House of quality

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Quality Function Deployment Identify customer wants Identify how the good/service will satisfy

customer wants Relate customer wants to product hows Identify relationships between the firm’s

hows Develop importance ratings Evaluate competing products

House Of Quality

Customerrequirements

Relationship matrix

Productcharacteristics

Importance

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Idea Generation Stage

Provides basis for entry into market Sources of ideas

Market need (60-80%); engineering & operations (20%); technology; competitors; inventions; employees

Follows from marketing strategy Identifies, defines, & selects best market

opportunities

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Customer Requirements Stage Identifies & positions key product benefits

Stated in core benefits proposition (CBP)Example: Long lasting with more power

(Sears’ Die Hard Battery)

Identifies detailed list of product attributes desired by customer Focus groups or

1-on-1 interviews

House of QualityHouse of Quality

Customer Requirements

Product Characteristics

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Product Characteristics

Functional Specification Stage Defines product in terms of how the

product would meet desired attributes

Identifies product’s engineering characteristics Example: printer noise (dB)

Prioritizes engineering characteristics May rate product compared

to competitors’

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Determines how product will be made Gives product’s physical specifications

Example: Dimensions, material etc. Defined by engineering

drawing Done often on computer

Computer-Aided

Design (CAD)


ProductCharacteristics

ProductCharacteristics

Component Specifications

Product Specification Stage

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Quality Function Deployment

Product design process using cross-functional teamsMarketing, engineering, manufacturing

Translates customer preferences into specific product characteristics

Involves creating 4 tabular ‘Matrices’ or ‘Houses’Breakdown product design into increasing

levels of detail

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To Build House of Quality Identify customer wants Identify how the good/service will satisfy

customer wants. Relate the customer’s wants to the

product’s hows. Develop importance ratings Evaluate competing ideas and concepts

Ultimately you choose the design Not the customer!

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You’ve been assigned temporarily to a QFD team. The goal of the team is to develop a new camera design. Build a House of Quality.

© 1984-1994 T/Maker Co.

House of Quality Example

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What the customer desires (‘wall’)

CustomerRequirements

CustomerImportance

Target Values

Light weightEasy to useReliable

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CustomerImportance

Target Values


3

12

Average customer importance rating

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CustomerImportance

Target Values


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Choose engineering characteristics to satisfy thecustomer requirements

AluminumParts

SteelParts

AutoFocus

AutoExposure

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CustomerImportance

Target Values


321

Relationship between customer attributes & engineering characteristics (‘rooms’)

AluminumParts

SteelParts

AutoFocus

AutoExposure

5 28 7

84 5 319 14 21 17

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QFD Cascades

Todd Krzycki 23

Adaptation of Piano Pedals for an Adult

Sample House of QualitySample House of Quality

Todd Krzycki 24

Project Description The Client has Multiple Sclerosis (MS)

which has taken her ability to use her right leg and more specifically for this project her right foot. We will design a pedal adaptation to utilize the Una Corda and Damper pedals with her left foot with out making her strain to reach the right pedal.

Todd Krzycki 25

Project Objectives Allow the client to use the Damper pedal

with minimal effort. Make a lightweight and small adaptive

device to make the right pedal accessible. Design a device that can be transported

easily from home to school and back. Avoid any sounds that could detract from

the piano.

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•The apparatus is going to The apparatus is going to be used by the left foot of be used by the left foot of the client. the client.

•Using hands or arms to Using hands or arms to activate the pedals is not activate the pedals is not feasible because that feasible because that would restrict the clients would restrict the clients playing ability.playing ability.

•Using your head or chin to Using your head or chin to activate the pedals is an activate the pedals is an option but it would make option but it would make the apparatus large and the apparatus large and hard to transport.hard to transport.

Apparatus UsageApparatus Usage

Jeff Adams 27

Electric Apparatus

Jeff Adams 28

Electric ApparatusPros•Easy to push the pedals Easy to push the pedals down. The electric down. The electric components will do the work components will do the work that would have been that would have been required by the client.required by the client.

•Compact. Electric Compact. Electric components are small and components are small and can be made to fit in a small can be made to fit in a small area.area.

•Apparatus would fit Apparatus would fit smoothly between and smoothly between and around the piano pedals.around the piano pedals.

Cons•Electric components are Electric components are costly making the over all costly making the over all cost of the project high.cost of the project high.

•Safety concerns with Safety concerns with electricity in the apparatus, electricity in the apparatus, as well as chemical concerns as well as chemical concerns if batteries are used.if batteries are used.

•Harder to move electric Harder to move electric components around to make components around to make it adaptable to multiple it adaptable to multiple pianos.pianos.

Jeff Adams 29

Mechanical Apparatus

Jeff Adams 30


Jeff Adams 31


Jeff Adams 32


Jeff Adams 33

Mechanical ApparatusProsPros•The components that go into a The components that go into a mechanical system are cheap mechanical system are cheap since the machining cost are since the machining cost are donated by UT.donated by UT.

•Reliable. You do not have to Reliable. You do not have to worry about a battery dying or worry about a battery dying or have to find plug to power the have to find plug to power the apparatus.apparatus.

•There is more feeling in the There is more feeling in the operations so it is easier to play operations so it is easier to play the damper pedal correctly. the damper pedal correctly.

•Light weight since light weight Light weight since light weight materials can be used and materials can be used and heavy batteries are not needed.heavy batteries are not needed.

ConsCons•A mechanical system will not A mechanical system will not allow play of the Damper as well allow play of the Damper as well as the Una Corda pedal with our as the Una Corda pedal with our clients limitations.clients limitations.

•It would have to be larger to It would have to be larger to allow for all the transfers of allow for all the transfers of motion in the system. motion in the system.

•The forces used to depress the The forces used to depress the pedals would have to be solely pedals would have to be solely supplied by the client. This may supplied by the client. This may become a concern if the client’s become a concern if the client’s condition worsens and they lose condition worsens and they lose more strength in their left foot.more strength in their left foot.

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Electric/Mechanical Apparatus

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Electric/Mechanical ApparatusProsPros•The Una Corda can be held down The Una Corda can be held down electrically allowing the client use of electrically allowing the client use of their left foot to use the damper pedal. their left foot to use the damper pedal.

•Having some electric components Having some electric components makes it easier to use the fixture in a makes it easier to use the fixture in a range of pianos. range of pianos.

•By having one electric component By having one electric component instead of two will use less power instead of two will use less power making the user less reliant on large making the user less reliant on large batteries. batteries.

•Having the damper pedal controlled Having the damper pedal controlled by mechanical means allows for more by mechanical means allows for more precise playing of the piano.precise playing of the piano.

•If no power supply is available the If no power supply is available the majority of the functionality of the majority of the functionality of the apparatus would still be intact.apparatus would still be intact.

ConsCons•Electric components are costly Electric components are costly making the cost of the over all making the cost of the over all project higher.project higher.

•Safety concerns with Safety concerns with electricity in the apparatus, as electricity in the apparatus, as well as chemical concerns if well as chemical concerns if batteries are used.batteries are used.

•Harder to move electric Harder to move electric components around to make it components around to make it adaptable to multiple pianos.adaptable to multiple pianos.

•Electrical components could Electrical components could cause noise that would distract cause noise that would distract from the sound of the piano.from the sound of the piano.

•Relying on electricity for part Relying on electricity for part of the design is a concern of the of the design is a concern of the client. client.

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House of Quality Importance Electrical Mechanical Electrical/ Mech.

Light Weight 8 8 4 6

Size 7 6 4 5

Universal design 8 8 4 7

Damper is primary pedal 9 4 8 8

Safety 10 6 8 7

Tactile Response 8 1 10 10

Cost 6 4 7 6

Noise 9 4 6 5

334 420 442

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House of Quality

Importance Solenoids Motors Hydraulics/Pneumatics

Light Weight 8 8 2 1

Size 7 9 6 5

Universal design 8 8 6 2

Damper is primary pedal 9 5 5 5

Safety 10 9 7 5

Tactile Response 8 5 5 5

Cost 6 4 6 8

Noise 9 9 6 6

471 351 296

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ROBUST DESIGN

Design that results in products or services that can function over a broad range of conditions

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What does Robust Design mean? Plan for variability Assess your capabilities Design for manufacturing Reduce costs Practice!

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Good Luck with your designs!

1 designing products and processes with a future

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