Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design

© 1999 © 1999 John W. NazemetzJohn W. Nazemetz

QFD and Concurrent EngineeringQFD and Concurrent Engineering

Discussion Topic 5 Discussion Topic 5

September 14, 1999September 14, 1999

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 2

Concurrent EngineeringConcurrent Engineering

Using QFD to Design a Using QFD to Design a Concurrent Engineering Concurrent Engineering

ProcessProcess

----

Discussion of AssignmentDiscussion of Assignment

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 3

Assignment (1)Assignment (1)• Assume you are a consulting firm Assume you are a consulting firm

which develops concurrent which develops concurrent engineering processes for client engineering processes for client companies. Using the QFD companies. Using the QFD methodology of Sullivan, develop a methodology of Sullivan, develop a series of matrices for your product series of matrices for your product (i.e., develop Figures comparable to (i.e., develop Figures comparable to Fig 4.5, 4.6, 4.7, 4.9 (hypothesize Fig 4.5, 4.6, 4.7, 4.9 (hypothesize competitors), 4.13). Note: all of these competitors), 4.13). Note: all of these figures are cumulative so one matrix figures are cumulative so one matrix which contains all of the information which contains all of the information will suffice.will suffice.

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 4

Assignment (Hint)Assignment (Hint)• Hint: you may wish/benefit from Hint: you may wish/benefit from

establishing a (multi-level) establishing a (multi-level) hierarchical grouping of hierarchical grouping of requirements, control characteristics, requirements, control characteristics, etc.-- this will help you in dealing etc.-- this will help you in dealing with your concepts as abstract with your concepts as abstract groups -- e.g., you may wish to use groups -- e.g., you may wish to use the abstract groupings Design, the abstract groupings Design, Process Planning, … and then use Process Planning, … and then use these to organize your thinking with these to organize your thinking with respect to customer requirements, respect to customer requirements, control characteristics, etc. control characteristics, etc.

© 1999 John W. NazemetzSlide 5 Computer Integrated

Manufacturing Systems

Typical ExperienceTypical Experience

• Theory/ProcessTheory/Process– Sounded Simple, Straight Forward

• ExecutionExecution– Difficult to Get Started

• Where to Start• Needed Logical Groupings/Categories

– Difficult Organizing Thoughts Coherently• Formatting Response

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 6

Customer Customer Requirements Requirements (1)(1)

• Typical Requirements (Customer Typical Requirements (Customer Terms)Terms)– More Effective Integration of

Engineering Activities– Establish New Design Paradigm/Culture– Reduce Time of Design– Reduce Cost of Design– Reduce Total System Costs– Gain Competitive Advantage– Reduce Post-Release Engineering Design

Changes

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 7

Customer Customer Requirements Requirements (2)(2)

• Typical Requirements (Customer Typical Requirements (Customer Terms)Terms)– Improve Customer Satisfaction– Improve Sales/Market Share– Reduce Manufacturing

Problems/Complaints– Enable Cross-Training/Discipline

Appreciation– Improve Communication– …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 8

Final Product Control Final Product Control CharacteristicsCharacteristics

• Probably Most Difficult Part of Probably Most Difficult Part of AssignmentAssignment

• Need to Use Viewpoints to Organize Need to Use Viewpoints to Organize ThinkingThinking

• Need Measurable System Need Measurable System Performance MetricsPerformance Metrics

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 9

Final Product Control Final Product Control CharacteristicsCharacteristics

• DesignDesign• ProduceProduce• Operate/EvaluateOperate/Evaluate• Maintain/ReviseMaintain/Revise• DisposalDisposal

• ManagementManagement• Customer’s Customer’s

CustomersCustomers• EngineeringEngineering• ManufacturingManufacturing• MaintenanceMaintenance• ……

Life Cycle Views Organizational Views

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 10

Final Product Control Final Product Control Characteristics Characteristics (Design 1)(Design 1)

• DesignDesign– Method Assures All Views Heard

• Structured Group Processes• Sensitivity Training• Effective Facilitors• …

– Method Assures All Views Considered• Value Engineering• Design for Manufacturing• Design for Assembly• …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 11

Final Product Control Final Product Control Characteristics Characteristics (Design 2)(Design 2)

• DesignDesign– Appropriate Design Tools/Aids Identified

and Made Available• CAD System Evaluation and Selection• CAPP System Design, Evaluation, Specification• Group Technology Design, Evaluation,

Implementation

– Method Assures Adequate Training Available

– Method Assures Training Taken/Learned– …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 12

Final Product Control Final Product Control Characteristics Characteristics (Produce 1)(Produce 1)

• ProduceProduce– Infrastructure Investment– Customization Expenses/Reusability– Documentation/Tool Development– Skills/Personnel Acquisition– …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 13

Final Product Control Final Product Control Characteristics Characteristics (Operate )(Operate )

• Operate/AssessOperate/Assess– Production Start-up Problems

• Contingency Funds Allowed/Spent per Project (Measure of Risk/Uncertainty)

– Number of Engineering Changes– Number of Personnel/Cost– Mean Time –to Product Design Re-

Engineering/Overhaul– Information Gathering/Exchange Costs – …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 14

Final Product Control Final Product Control Characteristics Characteristics (Maintain)(Maintain)

• MaintainMaintain– Recurring Consulting Fees/Visits– Personnel Re-Training Costs– Equipment/Tool/Method

Change/Replacement • Mean Time to Change/Replacement• Mean Time to Re-Organization of Function• Cost of Abandoned Tools/Practices

– …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 15

Final Product Control Final Product Control Characteristics Characteristics (Disposal)(Disposal)

• DisposalDisposal– Mean Time for Displaced Personnel to

Find New Position– Separation/Re-Training Costs– Lost Training Investment– Loss of Customer’s Customer Confidence – …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 16

Final Product Control Final Product Control Characteristics Characteristics

(Management)(Management)• Management ViewManagement View

– Cost to Develop– Marketability– Time to Develop Product– Time to Deliver Product– …

Computer Integrated Manufacturing Systems © 1999 John W. NazemetzSlide 17

RelationshipsRelationships

• Map Final Product Control Map Final Product Control Characteristics and Customer Characteristics and Customer RequirementsRequirements

• Hypothesize Markets, TargetsHypothesize Markets, Targets• IterateIterate

© 1999 John W. NazemetzSlide 18 Computer Integrated

Manufacturing Systems

Example Solutions - Example Solutions - ObservationsObservations

• Example 1Example 1– Analysis Performed at Higher Level of

Abstraction

• Example 2Example 2– More Detailed (More Rows, Columns)

• BothBoth– Scope/Coverage Very Similar– Details of Example 2 Map into Example 1 – Final Product Control Characteristics Not

Quantitative

Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design

© 1999 © 1999 John W. NazemetzJohn W. Nazemetz

QFD and Concurrent EngineeringQFD and Concurrent Engineering

Discussion Topic 5Discussion Topic 5

September 14, 1999September 14, 1999