Design for Excellence: Basic Introduction … · Poor reliability and manufacturability Stress...

Design for Excellence: Basic Introduction

NCAB Presentation

Dock Brown, CRE

206-892-8597

dbrown@dfrsolutions.com

Introduction to Design for Excellence

manufacturing!

reliability!

environment!

A Good Way to Begin – Some Cowboy Wisdom

o It ain’t what you don’t know that gets you into trouble.

o It’s what you know that ain’t so!

Today’s DfX Presentation

o General Concepts and Models

o Technical Environment

o Business Environment – $$$

o And Speaking of Money . . .

o DfM Modules

DfX: Design for the Full Product Life Cycle

Quality – the Essence of Excellence

Which is the higher quality camera?

Fitness for Use – ANSI Lock Grades

Fitness for Use – the Four Product Design Qualities

o Quality of Requirements

o Quality of Design

o Quality of Conformance

o Quality of Support

Example: Design of DC-10 Cargo Door

DfX – Central Concept Take-away

“The design must make it easy to do things right

and hard to do things wrong for it is fundamental

in human nature there is a chasm between what

people can do what they will do.” John McLucas, Chair, FAA

Quality of Requirements

o Voice of the Customer

o Paying Customer

o Permitting Customer

o Types of Requirements

o Present

o Future

o Projected

Quality of Requirements

o Fitness for Use

o Paying Customer

o Permitting Customer

o Reasonably Foreseeable Misuse

o Present

o Future

o Projected

o Use/Misuse Conditions

Attributes of a High Quality Requirement

√ Quality Attribute Definition

Structured <Who shall do What by When> or

Implementation-

States what is required, not how met

Necessary If removed, a deficiency will occur

Concise States ONE thing that must be done, and only what

must be done. Does not state what is NOT done.

Attainable Achieved based on an existing design concept

Complete Accurate quantitative parametric distribution

Consistent Does not contradict other requirements

Unambiguous One and only one interpretation

Verifiable Can be verified by either analysis, inspection,

demonstration or test

Correct Accurately describes functionality to be delivered

Modifiable Can be easily changed while retaining structure and

Let’s Continue With – A Little Professional Wisdom:

o Commenting on the utility of models; he said,

o “Essentially all models are wrong; however, some are useful.”

Risk Assessment Model

Perception/BeliefR

Risk Assessment Model – Technical & Business Risk

Perception/BeliefR

Bad GoodB

Reliability Model – Conceptual Product Space Product Use Conditions & Life Expectations

Satellites Military

Aircraft

Auto Safety Commercial

Aircraft

Outdoor

Signage

Utility

Monitoring

Chemical &

Petroleum

Production

Monitoring

Servers,

Routers,

Switches,

Storage

Auto Entertainment

Telecom Cell

Towers

Cell Phones Laptops Video Games Microwaves Washers

Toys iPods Desktop PCs Televisions Medical

Imaging

Dryers

Environm

Product Lifetime

Where’s the shift in RCG?

Reliability Model – Conceptual Product Space Technology Flow

Product Lifetime

ToysDesktop

LaptopsCell

Phones

Medical

Imagining

GamesMicrowaves

Servers

Routers

Switches

Storage

Entertainment

Chemical &

Petroleum

Utility

Monitoring

Commercial

Aircraft

Safety

Military

AircraftSatellites

Product Life Cycle Model

The Old Electronics Ecosystem

Ericsson

Fairchild Camera & Instrument

General Electric

Hewlett Packard

Marconi

Motorola

Mullard

Panasonic

Philips

Plessey

Siemens

Telefunken

Texas Instruments

Toshiba

Western Electric

Business Model

o Historical business model

o Dominated by vertically integrated companies

o Tech was the darling of the financial markets

o Well funded science, engineering, manufacturing

o Significant IP portfolios

o Used their own parts in their own products

o Baked into belief system

o High quality

o High reliability

o Long component lifecycles per EIA-724

o Today’s business model

o Thinly capitalized e.g. “debt zombie”

o Heavily outsourced structure

o Fragile joint ventures

Roadmaps

Roadmaps – Business and Technical

Roadmaps

Product Life Cycle ExperienceThe model is not the part, the map is not the terrain

What are Quantitative Parametric Conditions?

Use ConditionDistribution

In the knowledge journey toward

Quantitative Use/Misuse Conditions

we ask the following questions:

1. What is typical?

2. What is extreme?

3. How often does extreme occur?

Typical

Extreme

Probability of

extreme

Why is this

also referred

to as Stress

Distribution?

Probability of Failure

When do Use Conditions Cause Issues?

Stress Strength

Stress

Distribution

(Requirements

and Conditions)

Strength

Distribution

(Capability)

Poor reliability and

manufacturability

Stress

Distribution

Strength

Distribution

Strength

Increased

Stress

ReducedGood reliability and

manufacturability

Design and material choices

(DFM/DFR) can reduce

stress and increase strength.

Control maintains

separation of distributions

Use/Misuse Condition Knowledge Enables Quality

What is the Consequence of Reducing Use Condition Information to a Requirement?

Stress Strength

Use Conditions are often

reported as a single

requirement

What could go wrong if we

ignore the entire stress

distribution?

Use Conditions Cause Strength to Degrade Over Time

“time”

“force”

stress (use conditions) strength

Knowing how use conditions cause strength to degrade is fundamental for understanding the ‘physics of failure’

Example: things that wear out

Failure due to sudden overstress (e.g. shock)

“force”

“time”

stress (use conditions)strength

overstress event

Wear-out phenomena (e.g. fatigue)

“force”

“time”

u1 u2 u3

at t=0, s1=s2=s3u1<u2<u3

at t>0, s1>s2>s3

Product

Customer Needs

Super System

Component

y1 y2 y3

Sub System

System

Concept Engineering

Any Comments, Concerns, or

Thank you!

Dock Brown, CRE

206-892-8597

dbrown@dfrsolutions.com

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