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IntroductionIntroductionToTo
TRIZTRIZJohn Vandenbemden
QAIMaster Six Sigma Black Beltwww.trainingforQuality.com
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SS DMADV – A Cyclical Process
Define
AnalyzeAnalyze
Verify
MeasureDesign
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AnalyzeGenerate, evaluate and select the best concept that meet the CTQs within budget and resource constraints
Generate, evaluate and select the best concept that meet the CTQs within budget and resource constraints
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The Benefit of DFSS Innovation
• The time advantage of innovation
TimeAdvantage
Companies using Continuous Improvement & Continuous Innovation
Competition using onlyContinuous Improvement
Impr
ovem
ents
/ V
alue
Time
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Develop Design Concepts
Left Brain
•Functionality (FMEA)••TRIZTRIZ•Trend Analysis•Statistical Analysis
Right Brain
•Brainstorming•Brain writing•Assumption Busting•How lucky are you?
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Idea Generation Techniques
• Modified Brainstorming• Brainwriting• Assumption Busting•• TRIZTRIZ
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TRIZTRIZProjects frequently reach a point where the analysis is completed and the team is at a point where it is unclear where they need to go for resolution. This applies not only to projects but to problem solving, root cause analysis, or even Six Sigma (upon completion of the analysis phase). The project team must be creative in order to determine what to do next. TRIZ minimizes the chance of unpredictable and unrepeatable results that are associated with brainstorming or brainwriting.
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TRIZTRIZ• TRIZ is based on the idea that many of
the underlying “root” problems that engineers face today contain elements that have already been solved (approximately 90%), often in a completely different industry, for a totally unrelated situation, that uses an entirely different technology.
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• The most important recognition is that “technical systems evolve”– Which evolves towards the
increase in ideality• By overcoming Contradictions
–Achieved primarily with the minimal introduction of resources
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T.R.I.Z. (Trez or trees)Theoria Resheneyva Isobretatelskehuh ZadachTheory of Inventive Problem Solving
– Developed after WWII (1946) by GenrichAtschuller (1926-1998), a Russian inventor and naval officer. He was sent to the Siberian Gulag camp by Stalin for thinking too much. He was released from prison after Stalin’s death.
– Based on a theory that there are universal principles of inventive and creativity.
– TRIZ is structured method that can be used to rapidly generate plausible concepts that solve problems in technical and non-technical domains.
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Altschuller / T.R.I.Z. • Started with 400,000 patients, today it
includes the study of more than 2.5 million patients.
• Altschuller discovery:– Each innovative patient solves a technical
problem, but across domains, there are common solutions. These solutions were boiled down to 40 principles.
– Inventive problems often carry with them inherent contradictions. (e.g. stronger, but heavier)
– Anyone can use this knowledge and methodology to solve problems.
– Resources are often idle during problem solving.
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TRIZ’s Inventive Principles1. Segmentation2. Extraction, taking out3. Local conditions, quality4. Asymmetry5. Combining, merging6. Universality7. Nesting8. Anti-weight9. Prior counter-action10. Prior action11. Cushion in advance12. Equipotentiality13. Inversion14. Spheroidality15. Dynamicity16. Partial-excessive action17. Shift to a new dimension18. Mechanical vibration19. Periodic Action20. Continuity of useful action
21. Rushing through skipping22. Convert harm into blessing23. Feedback24. Mediator25. Self-service26. Copying27. Disposable object, cheap28. Replacement of mech. system29. Use pneumatic or hydraulic30. Flexible film or thin membrane 31. Use porous material32. Change color33. Homogeneity34. Rejecting and regenerating parts35. Transformation of phys and chem.36. Phase transition37. Thermal expansion38. Use strong oxidizers39. Inert environment40. Composite materials
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TRIZ MethodUnderstand the problem as a
system
Understand the Understand the problem as a problem as a
systemsystem
Locate conflictsLocate Locate
conflictsconflicts
Identify Resources
Identify Identify ResourcesResources
Systematically explore solutionSystematically Systematically
explore solutionexplore solution
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TRIZ
Thus;
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The Three Premises of TRIZ• Ideality (ideal solution)• Resolve Contradictions• System Approach
TRIZ Approach/Tools• Innovation Situation Questionnaire (ISQ)• Problem formulator• Substance-Field Analysis (Su-Field)
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Why TRIZ ?• Simply stated, we need to create
innovative products and services to remain competitive !– We need to significantly improve the
engineers ability to quickly solve difficult and seemingly impossible engineering problems which often lead to next generation “innovative” products.
Creative Problem Solving!Creative Problem Solving!Creative Problem Solving!Provides a Dialectic Way of Thinking!Provides a Dialectic Way of Thinking!Provides a Dialectic Way of Thinking!
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The Innovation LeverThe Innovation Lever
TRIZKnowledge
InnovativeSolutions
IndustryKnowledge
CompanyKnowledge Your
Knowledge
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Example
• Generic problem solving, think in broad terms:– Principle #3 Local Conditions / Quality
– Airport with smoking areas– Yard light with a photocell– Pen with an eraser
• Combine several techniques and tools to enhance problem solving
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Altschuller Contradiction Matrix• The 40 Inventive Principles can be utilized to solve
problems but unfortunately, fixing one problem often results in creating another problem.Examples: – Companies buy other companies to grow and
strengthen themselves. This often results in a company disorganized and less stable.
– Coffee should be hot for enjoyable drinking but cool enough to prevent burning the drinker.
– Bandwidth increases (Good) but requires more power (bad)
– Training increases competence (Good) but requires employees to be away from their job responsibilities (bad).
• These contradictions can be resolved by applying the Contradiction Principles in a Contradiction Matrix.
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Altschuller Contradiction MatrixAs you can see from the examples on the previous slide there are two categories of contradictions.
1. Technical contradictions are based on classical engineering of “trade-offs.” The desired state can not be obtain because there is a barrier in the system.
2. Physical contradictions (Inherent) are situations in which one object or system contradicts the requirements of the other.
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Contradiction Principles1. Weight (of object in motion)2. Weight (of stationary object)3. Length (of object in motion)4. Length (of stationary object)5. Area (of object in motion)6. Area (of stationary object)7. Volume (of object in motion)8. Volume (of Stationary motion)9. Speed10. Force or Intensity11. Stress or Pressure12. Use of Energy (of object in motion13. Use of Energy (of stationary object)14. Duration of Action (of object of motion)15. Duration of Action (of stationary object)16. Temperature17. Illumination intensity18. Difficulty in monitoring or measuring19. Productivity20. Object generated harmful effects
21. Shape22. Stability23. Strength24. Power25. Losses of energy26. Losses of substance27. Losses of Information28. Losses of Time29. Quantity of Substance30. Reliability31. Measurement Accuracy32. Manufacturing Precision33. Harmful external effects34. Ease of manufacturing35. Ease of operation36. Ease of repair37. Adaptability or versatility38. Device complexity39. Extent of automation
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ContradictionsContradictions appear first as a gap between demands and supplies. They are overcome by break-through inventions. These inventions form the micro-steps of evolution in technical systems. Since the solutions are not known, creative problem solving is the method utilized to overcome contradictions.
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Contradiction Matrix
• Are a result of Altschuller’s patent research• The principles are technical characteristics• Can be applied throughout the Six Sigma
DMADV process whenever conflicts or contradictions arise.
• It is a large table that link pairs of the engineering principles (39 X 39 matrix).
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Contradiction MatrixWorsening Feature
Improving Feature
Weight of moving object 32, 21 12, 5 –
Weight of stationary object 32, 21 – 6,9, 23,31
Length of moving object 12, 5, 34 – 1, 5
Length of stationary object – 6,9, 23,31 1, 5
Weight of moving object
Weight of stationary
object
Length of moving object
Length of stationary
object
Inventive Principle that can be utilized to
identify a solution
Inventive Principle Inventive Principle that can be utilized to that can be utilized to
identify a solutionidentify a solution
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Contradiction Matrix
The core process is to drive a physical contradiction (using the matrix) and solve it with the Separation Principle. Once the physical contradiction is determined this solution technique is powerful enough to identify break-through (innovative) solutions.
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TRIZTRIZ works and is used by large as well as small organizations on several levels to solve real, practical everyday problems. TRIZ is utilized at companies such as Ford, Motorola, Proctor & Gamble, Eli Lilly, 3M, LG and …
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Summary
Innovative concepts are critical and a necessity to drive the optimization efforts to design new products or redesign exsisting processes or products.