TEAM 06

Aniruddha Srinath

Ketan Bapat

Pulkit Agrwal

Syed Rehan Ahmed

MFG599: DESIGNING IN QUALITYA DESIGN FOR SIX SIGMA COURSE

Drake Droplets

Agenda• Project Overview- Mr. Ketan

• IDD-Identify- Mr. Rehan

Project Charter

Project Plan

Project Prioritization Matrix

Customer requirement

• IDD-Define- Mr. Aniruddha

Voice of Customer-CTS Matrix

Kano Analysis

House of Quality

Design Scorecard

• IDD-Design- Mr. Pulkit

Benchmarking, lateral thinking & TRIZ

Design Alternatives

Pugh Matrix

Final Design Concept

IDD – Project Overview

• Product: Refrigerator

• Target market: United States

• Target customers: Family

IDD – Project CharterProject Charter

Project Information Resources

Project #: Grn-Ref-12-01 Champion 1 Aniruddha Srinath

Project Name: Refrigerator Champion 2 Ketan Bapat

Project Start Date: 8-Feb-12 Champion 3 Pulkit Agarwal

Project End Date: 21-Feb-12 Champion 4 Rehan Syed

Problem Statement:

Goal Statement:

Project Scope

Our company ( a multi-product conglomerate) has recently adapted a new sustainability policy which requires all it's

divisions to reform their businesses towards creating and selling environment-friendly products. Since the release of freons

from refrigerators is a big debate in the environment world, our company has specifically asked the refrigerators division to

come up with new green solutions

The goal of this project is to design a "Green Refrigerator" with reduced greenhouse emission ( kg per kilowatt hour), lower

electricity bills ($ ), high reliability (number of years without service) and warranty rates (number of complaints per year)

This project will focus on developing a new referigerator. We will focus on the functional aspects of the case, specifically the

referigerant gases emission and the power consumption and also improve the performance in terms of reliability and

durability.

IDD – Project Plan

8 9 10 11 12 13 14 15 16 17 18 19 20 21

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan ∆

Actual

Plan ∆Actual ∆Plan ∆Actual

Working Schedule-Referigerant Project

Define- Kano Matrix

Aniruddha

Aniruddha

Aniruddha

Aniruddha

Rehan

Rehan

Rehan

Identify-Project

Prioritization Matrix

5.b

4.a

4.b

Report making

Design- Final Concept

Pulkit

Pulkit

Ketan

Ketan

3.d

pulkit

Pulkit

4.c

4.d

5.a Presentation preparation

Presentation co-

ordination

3.a

3.b

3.c

1.a

1.b

1.c

2.a

2.b

2.c

5.c

Team

Team

DescriptionEvent

February

Design- Benchmarking &

TRIZ

Design- Design

Alternatives

Design- Pugh Matrix

Define-House of Quality

Define- Design Scorecard

Identify- Project Plan

Job Allocation

Customer Requirements

Define- CTS Matrix

Introduction and job

responsibility allocation

Problem desrciption &

assumptions

Identify- Project Charter

Team

Ketan

IDD – Project Prioritization MatrixGR-Green Referigerants

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Tim

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Go

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ost

# Project Name Y/N Y/N Y/N List #Rating (1..5)

5 4 2 2Hard

Savings

Soft

Savings

1 Reduce CFC emissions by 10% N Y N 7,8 9 1 3 1 57 2 $XX $XX

2 Reduce power consumption by 15% N Y N 8 9 3 3 3 69 1 $XX $XX

3 Eliminate electric shock Y Y N 9 1 1 1 53 4 $XX $XX

4 Reduce EMF to less than 50 v/m N N Y 1 1 3 1 17 8 $XX $XX

5Improve reliability (no of hours

before repair)N Y N 3 3 3 3 39 5 $XX

6 Reduce warranty claims by 15% N Y N 5 3 3 3 3 39 5 $XX $XX

7 Reduce cost by 15% N Y N 1,2,5,6,8 3 9 1 1 55 3

8 Increase storage capacity by 20% N Y N 7 1 3 1 1 21 7 $XX

Estimated

Annual Savings,

$$

Selection Criteria

Se

lecti

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Cri

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ati

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s

(Lo

w=

1;

Me

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m=

3;

Hig

h=

9)

Project FILTERS (Y/N)?

Pro

ject

Pri

ori

ty

Ra

nk

IDD – Customer Requirements

Customer Survey/Focus Group

Sampling

21 Families

Voice of Customers-CTS Matrix

Customer RequirementsKano

Classification

Customer

Importance

Rating

CTS Metric CTS Goal

Is safe to use Basic 4no of

accidents/year0

No odor Basic 5 yes/no No

Easy to clean Basic 3 time in minutes <30 mins

Long time freshness of food Basic 4 yes/no Yes

Has long life Excitement 3 MTBF >7 years

Have temperature control Excitement 2 have/not have have

Door Inbuilt water dispenser Excitement 2 have/not have Have

Fast chilling for making ice cubes Excitement 2 have/not have Have

Has high warranty Excitement 4 no of years >3

Has adjustable compartments Revealed 5 yes/no yes

More number of compartments Revealed 4 nos 15

Costs less to purchase Revealed 3 price in $ <1450

Is environment friendly Revealed 3CFC emission

(kg/hr)<0.5

Have automatic features Revealed 2 yes/n yes

IDD – Kano Analysis

• Kano Analysis:

– Table below summarizes must be, one-dimensional, and delighters

• Potential Delighter – Automatic control features

– Survey sample size was 21

IDD – Kano Analysis Result

House of Quality

Design Scorecard

Benchmarking Analysis:

Adjustable Shelves Water Purifier Eco-friendly (low CFC emissions) Rapid Ice making

• Lateral Thinking:

Provocative Statement: We are no longer using refrigerator as standalone unit.

TRIZ Contradiction Analysis:1.

Feature Trying to Improve: Number of Compartments Contradictory Feature to Mitigate: Volume/Storage Space

2.

Feature Trying to Improve: Time Required for Making Ice Contradictory Feature to Mitigate: Power Consumption

3.

Feature Trying to Improve: Number of Compartments Contradictory Feature to Mitigate: Time Required for cleaning

4.

Feature Trying to Improve: Automatic Control Features Contradictory Feature to Mitigate: Power Consumption

Exterior Design Alternatives

Pugh Matrix

Pugh Matrix for door/mounting type

Pugh Matrix for automatic controlTitle Automatic Control

Project

Name

Date

Decision Criteria

Item RequirementOverall

ImportanceManual Type

Semi

Automatic

Fully

Automatic

1 Power consumption 29 0 -1

2 Ease of operation 20 +1 +2

3 Keeping food fresh for a long time 22 +1 +2

4 No presence of odor 15 +1 +1

5 Cost of manufacturing 10 0 -1

6 Warranty 4 0 +1

100

Counts

Count of Pluses 3 4 0

Count of Minuses 0 2 0

Count of Same (0) 3 0 0

Pluses - Minuses 3 2 0

Sums

Sum of Pluses 3 6 0

Sum of Minuses 0 -2 0

Total 3 4 0

Weighted Sums

Weighted Sum of Pluses 57 103 0

Weighted Sum of Minuses 0 -39 0

Total 57 64 0

D

a

t

u

m

Add Row

Add Col

Make Datum

Delete

Final Design Concept

• Energy Star Certified- 15% lesser power consumption

• HCFC-22 & HFC-134a-12%

• LCD display

• Integrated Drawer type shelves

• LED lighting

• Ice and water dispensing

• Temperature controlled zones

• Adjustable horizontal and vertical dividers

• Electronic adjustable temperature control

• 7 years life period

• Cost- $1450

Aniruddha Srinath Ketan Bapat Pulkit Agrwal Syed Rehan

Thank You!

Questions??