IE 496 - Robust Design and Engineering

Dr. Suat Genc

Part-time Assistant Professor Department of Industrial Engineering Bogazici University Lecture 1: Introduction

Introduction to RD&E

BU Industrial Engineering Department

Lecture 1 Page 2 - Fall 11

Genc

Right at the beginning

Whatever you learn at school has:
a scientific (academic) use and value
&

a commercial use and value

So, think about how you can commercialize what you learn here! Please keep this in mind all the time throughout the semester!

BU Industrial Engineering Department

Lecture 1 Page 3 - Fall 11

Genc

Why bother?
A commercial business, ideally, aims to possess a competitive advantage with respect to competitors and the ability to sustain in the global marketplace for a long time.
Competitiveness

Sustainability Fortune 500 List - 2006

In business more than one century

BU Industrial Engineering Department Lecture 1 Page 4 - Fall 11 Genc

The requirements for success

In order to have a competitive edge and sustain in the market, a company should have ability to produce high quality products at low cost in a short time.
Competitiveness Requirements List
High quality Low cost Short time-to market

BU Industrial Engineering Department

Lecture 1 Page 5 - Fall 11

Genc

What does quality refer to?

There are eight broad dimensions of quality. These are: Performance
Will the product do the intended job?

Reliability
How often does the product fail?

Durability
How long does the product last?

Serviceability
How easy is it to repair the product?
BU Industrial Engineering Department Lecture 1 Page 6 - Fall 11 Genc

What does quality refer to?

Aesthetics
What does the product look like? (Related to appearance, smelling, touching, hearing, and tasting)

Features
What does the product do?

Perceived quality
What is the reputation of the company or its product?

Conformance to standards
Is the product made exactly as the designer intended?
Lecture 1 Page 7 - Fall 11 Genc

BU Industrial Engineering Department

Cost Contributors
Retail Price

Retailer Profit Warranty, Insurance, etc. Distribution Cost

Manufacturer Price

Manufacturer Profit

Manufacturing Cost Raw Material Infrastructure Energy (manpower, etc.)

BU Industrial Engineering Department Lecture 1 Page 8 - Fall 11 Genc

Time-to-Market

Market
Market Research Planning Development Manufacturing Packaging Control Market Service

Customer
BU Industrial Engineering Department Lecture 1 Page 9 - Fall 11 Genc

Cash drains in product development

There are ten problems that cause new products to be too slow in development, too expensive, lacking in quality, and not satisfying customers. Technology-Need Mismatch Disregard for the Voice of the Customer Premature Concepts Pretend Design Pampered Design Hardware Swamp Weak Design for Producibility Lack of Process Optimization Inspection Poor Team Work
BU Industrial Engineering Department Lecture 1 Page 10 - Fall 11 Genc

Cash drains
Cash Drain 1: Technology and Need Mismatch Technology development has 3 problems: Clever technology is developed that does not satisfy customer needs There are strong customer needs for which technology generation activities are lacking Good concepts are developed for which there are clear customer needs, but new technological concepts are inadequately transferred into the development of a specific product Technology must be responsive to the customer and effectively implemented in products
BU Industrial Engineering Department Lecture 1 Page 11 - Fall 11 Genc

Cash drains
Cash Drain 2: Disregard of the Voice of the Customer The first step in the development of a specific new product is the determination of the customer needs. In traditional approach the activity of the identifying customer's needs is not well completed, and the biggest problem has been the deployment of the voice of the corporate specialist rather than the voice of the customer (VoC). Attention to the voice of the customer is a key success factor!
Genc

BU Industrial Engineering Department

Lecture 1 Page 12 - Fall 11

Cash drains
Cash Drain 3: The Premature Concept (vulnerable concepts) Many concepts look good in the first stage. However, six months after they are rushed into prototypes and they are found to be vulnerable. It is a tremendous cash drain to waste resources on a concept that then becomes recognized as highly vulnerable even before the product reaches the market.

Concepts should stand the test of competitive evaluation.

Genc

BU Industrial Engineering Department

Lecture 1 Page 13 - Fall 11

Cash drains
Cash Drain 4: Pretend Design Pretend Design are new but not better! They are not production intended designs. The lack of production intend leads to the attitude oh, well, this is just the first design, we will fix this later

Producibility and competitive superiority must be designed in from the beginning.

Lecture 1 Page 14 - Fall 11 Genc

BU Industrial Engineering Department

Cash drains
Cash Drain 5: Pampered Product Most products work well under some particular conditions. The traditional approach is to pamper the product to make it look better. The product is not seriously challenged but rather is pampered by special tuning so that it works for demonstration purposes.

The product should be designed to work under a wide range of conditions so that the performance remains close to ideal customer satisfaction. This is called Robust Functionality

BU Industrial Engineering Department

Lecture 1 Page 15 - Fall 11

Genc

Cash drains
Cash Drain 6: Hardware Swamp
Hardware swamps occur when the prototype iterations are so numerous and overlapping in time that the entire team becomes busy with debugging and maintaining the experimental hardware. The hardware swamp becomes so severe that no time remains to improve the design. The team cannot complete any organized experiments because of the time and effort going into debugging and maintaining the hardware

Early optimization of Robust Functionality avoids the excessive number of prototypes and experimentations and thus prevents the occurrence of hardware swamps.
BU Industrial Engineering Department Lecture 1 Page 16 - Fall 11 Genc

Cash drains
Cash Drain 7: Weak Design for Producibility In the traditional approach a product has been developed to an almost final stage without considering how to produce it. This is a sure road to failure.

The production capability along with the product design must be developed.

BU Industrial Engineering Department

Lecture 1 Page 17 - Fall 11

Genc

Cash drains
Cash Drain 8: We have always made it this way! (Lack of Optimization). We have always made it this way, and it works! But has the production capability been optimized to achieve minimum cycle time and more quality?

The critical processes must be optimized to achieve customer satisfaction and increase throughput.

BU Industrial Engineering Department

Lecture 1 Page 18 - Fall 11

Genc

Cash drains
Cash Drain 9: Inspection Inspection is the process to sort the good products from the bad ones after the production. This is now widely recognized as a poor process for most products.

Eliminate the need for inspection on a mass basis by building the quality into the product in the first place.

BU Industrial Engineering Department

Lecture 1 Page 19 - Fall 11

Genc

Cash drains
Cash Drain 10: Poor Team Work Give me my targets, let me do my thing! Targets seem good, but they tend to limit improvements. Also, allocation of targets down to a detail level tends to destroy team work.

Isolated work leads to destroy team work and leads to subsystems that cannot be integrated, products that cannot be produced and other problems. Team work and better management practices are needed!
BU Industrial Engineering Department Lecture 1 Page 20 - Fall 11 Genc

10

Total Quality Development

A relatively new design methodology, Total Quality Development, has been developed to overcome problems in product and process development. Total Quality Development utilizes three disciplines as the following:
Basic Concurrent Engineering Quality Function Deployment (QFD including House of Quality) Taguchi Robust Design

The course focus

BU Industrial Engineering Department Lecture 1 Page 21 - Fall 11 Genc

Product realization process

STAGES
Need (Market) Development & Design Concept Generation Prototyping Concept Evaluation Manufacturing Subsystem Specs Testing & Verif. Sell Recycle Subsystem Design Piece-Part Design Planning and Specs

TOOLS
House of Quality (VoC/TS Matrix) Concept Generation Tools Concept Evaluation Tools QFD (TS/SS Matrix) Taguchi Parameter D. (SS/PP Matrix) Taguchi Tolerance D. (PP/Process Matrix)

BU Industrial Engineering Department

Lecture 1 Page 22 - Fall 11

Genc

11

Design decisions
A complex product may include millions of decisions to carry it into production and into the market place.
Individuals make most product development decisions using experience, analysis, handbooks, and computerized records (10 million decisions). Multi-functional teams make decisions using a disciplined approach, i.e., QFD (1000-10000 decisions). Systematic optimization is used for critical decisions, i.e., Robust Design (several hundred decisions).
300-500 Decisions given during R&D Robust Design QFD Basic Science
Lecture 1 Page 23 - Fall 11

1.000-10.000

10.000-10M
BU Industrial Engineering Department

Competitiveness provided by the Tools

Genc

Robust Design

BU Industrial Engineering Department

Lecture 1 Page 24 - Fall 11

Genc

12

A sample quality characteristic

LSL USL

Bread toaster Bread slices

Target

Quality Characteristic: Color

BU Industrial Engineering Department

Lecture 1 Page 25 - Fall 11

Genc

Applying Robust Design

Robust Design
Target

Manufacturing variability Environmental effects Usage

Specification Limit

Specification Limit

BU Industrial Engineering Department

Lecture 1 Page 26 - Fall 11

Genc

13

Robust Design
Robust Design was introduced to Engineering Community by Dr. Genichi Taguchi. Dr. Taguchi defines robustness as: The state where technology, product or process performance is minimally sensitive to factors causing variability (either in manufacturing or in use) at the lowest unit manufacturing cost.

Robustness is the goal of the Robust Design

BU Industrial Engineering Department

Lecture 1 Page 27 - Fall 11

Genc

Some of the RD Users

Robust Design is the major factor behind Made in Japan quality!!!

BU Industrial Engineering Department

Lecture 1 Page 28 - Fall 11

Genc

14

Robust System
Non-Robust System Input Signal
Internal & External NOSES

Output

Sistem
Response

Changing System Performance

Robust System Input Signal

Output

Sistem
Response

Stable System Performance

BU Industrial Engineering Department

Lecture 1 Page 29 - Fall 11

Genc

Parameter-Output Relationship
Output Response (y)
Low Variance

y2

y
y

The relationship between system parameter and output response

High Variance

y1

x
x1

Provides more robust solution

x2

Parameter (X) affecting the System Performance

BU Industrial Engineering Department

Lecture 1 Page 30 - Fall 11

Genc

15

Measuring robustness
Robustness of a product can be measured using following metrics:
Reliability Data Rework Rate Scrap Rate % Defective Warranty Information

The problem with relying on these measures to evaluate robustness is that they come late in the product development cycle. Taguchi suggest using Signal-to-Noise Ratio at the R&D stage.
BU Industrial Engineering Department Lecture 1 Page 31 - Fall 11 Genc

Signal-to-Noise Ratio
Signal-to-Noise (S/N) Ratio
Signal: Noise :
S/N =
S/N = S/N =

Desired, useful system output Undesired, useless, harmful system output

Energy (or power) that is transformed into intended output Energy (or power) that is transformed into unintended output Useful Output Energy Harmful Output Energy Work done by Signal Work done by Noises The higher the ratio, the more robust the function is.

BU Industrial Engineering Department

Lecture 1 Page 32 - Fall 11

Genc

16

S/N Ratio Example

Input System Signal (useful) Noise (harmful)

S/N =

Power of the signal that is heard Power of the noise that is heard
Signal
NOISE

NOISE NOISE

Signal Signal

NOISE
NOISE

NOISE

INPUT SIGNAL

Signal NOISE NOISE Signal NOISE NOISE NOISE Signal NOISE Signal Signal NOISE Signal Signal Signal NOISE NOISE NOISE NOISE NOISE Signal NOISE NOISE NOISE NOISE Signal NOISE Signal NOISE NOISE NOISE NOISE NOISE NOISE Signal

NOISE
NOISE

NOISE

Signal
NOISE

Signal

NOISE
NOISE

NOISE

NOISE

NOISE

NOISE

Signal

NOISE

NOISE
Signal

NOISE Signal NOISE

Signal

BU Industrial Engineering Department

Lecture 1 Page 33 - Fall 11

Genc

Why S/N Ratio, not Efficiency?

Input System Useful Output 100 99 98 97 Harmful Output 0 1 2 3 Efficien cy (%) 100 99 98 97 S/N Ratio Infinity 99 49 32 Output

Input 100 100 100 100

Efficiency (%)

Not sensitive to harmful output Deviation from ideal output (harmful output)

Deviation from ideal output (harmful output)

Genc

BU Industrial Engineering Department

Lecture 1 Page 34 - Fall 11

S/N

Sensitive to harmful output

17

Focus on what Customer sees

Focus on desired output, not harmful one to kill two birds with one stone!
Input
System

Useful Input
System

Useful

Harmful Focusing on Harmful Output

Harmful Focusing on Useful Output

What customer sees IMPROVED DESIGN

What customer do not see

LTL

UTL

LTL
Lecture 1 Page 35 - Fall 11

UTL

LTL

UTL
Genc

BU Industrial Engineering Department

Engineering Systems
There are 4 components in technical or engineering systems. These are:
Input signal Control factors Noise factors Output response

Technical System

Control Factors (C) Input Signal (M) Output Response (y)

Sistem

Noise Factors (N)

BU Industrial Engineering Department Lecture 1 Page 36 - Fall 11 Genc

18

Example Systems
What are the input, output, control and noise factors for the following systems?
Battery Wind Turbine

Heater

Scale

BU Industrial Engineering Department

Lecture 1 Page 37 - Fall 11

Genc

System Development Stages

STAGES
Need (Market) Development & Design Concept Generation Prototyping Concept Evaluation Manufacturing Subsystem Specs Testing & Verif. Sell Recycle Subsystem Design Piece-Part Design Planning and Specs

TOOLS
SYSTEM CONCEPT DEVELOPMENT
Genc

House of Quality (VoC/TS Matrix) Concept Generation Tools Concept Evaluation Tools QFD (TS/SS Matrix) Taguchi Parameter D. (SS/PP Matrix) Taguchi Tolerance D. (PP/Process Matrix)

BU Industrial Engineering Department

Lecture 1 Page 38 - Fall 11

ROBUSTNESS DEVELOPMENT

19