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Lecture 3-1
Design Review
Concurrent Engineering
MIL STD 1629
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Survey Results FMEA
A structured design process strategy is in place.
Your organization documents previous designs and processes
and makes them accessible to design teams.
Your organization uses guidelines, checklists, or documentation
of best practices.
Your design teams explicitly record observations and
assumptions throughout the design process.
There are regularly scheduled design reviews.
The design managers use performance metrics to evaluate the
design process.
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Common Causes of Error
FMEA
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Typical Survey Comments
FMEA
• “[Design errors are the result of working to schedules that are
often unrealistic and not well-designed by project managers.”
• “Recently, there has been a change in policy that NO redlined
drawings are to be accepted for producing production or
prototype parts. This should be common sense, but with schedule
pressure/deadlines, rules get bent.”
• “Design reviews are the only means of identifying and preventing
design errors. In the 6 years that I have been here, I have never
done nor have been asked to do a FMEA.”
• “Have attempted [FMEA-type analysis on design process] on
several occasions but have not committed enough resources or
time to see it through.”
• In the past, this [FMEA] has not been a regular process, but this
analysis has been encouraged and is being done by some, but it is
far from what I would call standard operating procedure.”
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Reliability Analysis Methods
FMEA
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Design Review FMEA
• Early Warning of New Product Problems
New Product Phase Early Warning
Concept, feasibility Concept Review
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Today’s Environment FMEA
Modern products need a structured program
• DR’s are mandatory - customer or management
• Conducted by a team of specialists not directly
associated with the development of the design
• Ultimate decision rests with the designer
• DR’s are formal
• Topics include reliability, performance, producibility,
serviceability, maintainability, interchangeability,
safety, appearance, cost, value
• Reviews made to defined criteria
• Conducted at several phases of the design
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Concurrent Engineering FMEA
1. A systematic approach
2. to the integrated, concurrent development of a
product and its related processes
3. that emphasizes response to customer expectations
4. and embodies team values of cooperation, trust and
sharing
5. in such a manner that decision making proceeds with
large intervals of parallel working
6. by all lifecycle perspectives
7. synchronized by comparatively brief exchanges to
produce consensus
Determining
User Market Preparation
the basic Sales
Investigation Investigation for Sales
need
Integrated Product Development, Andreasen, M.M. and L. Hein, Berlin: Springer, 1987
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Concurrent Engineering Toolbox FMEA
Taking into account all lifecycle perspectives requires
structured working methods. Various tools have been
developed to support these working methods:
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Quality Function Deployment FMEA
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• A process is robust if it is
– flexible,
– easy to operate,
– error-proof
– its performance will tolerate uncontrollable
variations in external and internal factors
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Design for Manufacturability FMEA
Design for Manufacturability (DFM) may be defined as
an approach for designing products so that:
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Where Did the Org Chart Come From? FMEA
Look familiar?
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See speaker’s notes
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Concurrent Engineering FMEA
DESIGN ENIGNEERING
PROCESS PLANNING
MANUFACT. ENGINEERING
TOOLING
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The Danger of Suboptimization FMEA
Optimization - is a process of orchestrating the efforts of all
components toward achievement of a stated aim. Optimization
is management’s job. Everyone wins with optimization.
Suboptimization - the maximizing or fine-tuning of a part of
the system
We need to work together to optimize the system as
a whole, not seek to optimize separate pieces. -
Deming
Optimizing separate pieces
destroys the effectiveness
of the whole.
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Suboptimization FMEA
Anything less than optimization of the whole system will
bring eventual loss to every component in the
system. Any group should have as its aim
optimization of the larger system that the group
operates in.
W. Edwards Deming
The New Economics for Industry, Government and Education
MIT Center for Advanced Engineering Study, 1993
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DFMA FMEA
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DFA FMEA
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DFMA FMEA
DFMA contributes to competitive success
by matching product demands to
manufacturability and assembly capability
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DFMA FMEA
Major characteristics of DFMA include:
• both manufacturing and assembly are
taken into consideration in the
optimization of the design.
• By parallel execution, the effect of a
design decision on production can be
evaluated, at the moment that the decision
is made
• Commitment to continuous production
and process optimization.
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FMEA
Process FMEA
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Handbook Pg. 30
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Process FMEA FMEA
identifies potential product related process failure
modes,
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Understanding variation FMEA
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