OPTIMIZING THE DESIGN CHANGE PROCESS

Optimizing the Design Change Process for Product Quality

Abstract

This study highlights the role of optimizing the design change process for increasing product quality,especially from a automobile industry perspective. The study highlights the importance of design quality and shows how effective design quality methods such as QFD can improve the quality of a product and increase its effectiveness. In sum the study covers many aspects of design change and optimization in relation to product quality.



Table of Contents

Abstract2

Chapter 1: Introduction4

Overview of the Study4

Research Question4

Rationale5

Significance of the Study7

Chapter 2: Literature Review9

Why do we need QFD?10

QFD process11

What are the benefits of QFD?17

Quality Function Deployment: A Teamwork Approach17

ISO 9000 quality systems serfs32

Quality function deployment33

Chapter 3: Discussion36

Chapter 4: Methodology and Conclusion50

Research Method50

Literature Selection Criteria50

Search Technique50

Keywords Used51

Theoretical Framework51

Interviews51

Conclusion52

References53

Appendix60

Chapter 1: Introduction

Overview of the Study

Quality is conformance to engineering requirements as described in drawings, specification and related documents. Product quality was assessed against engineering requirements by intensive inspection, audits and other checks. Traditionally conformance checks were carried out by the quality control department.

An approach to quality based on defect detection is inevitably heavily biased downstream in the product cycle since conformance to engineering specification is most easily assessed by measurement of finished or at least partly finished product.

Quality Function Deployment (Eureka & Ryan, 1988; Ryan, 1988; Dale & Plunkett, 1990) is a technique which encourages direct cross functional involvement in product quality. This involvement starts at a very early upstream conceptual stage of product development. It continues through the planning stages necessary for the design of both product and the process which will manufacture the product and the subsequent implementation of the process on the factory floor. QFD is a disciplined process whereby customer requirements, as identified by the customer, are translated directly into design requirements and subsequently deployed into product characteristics.

Research Question

How can quality design methods improve the overall quality of a product?

Rationale

In the initial phase of QFD customer requirements (Whats) are translated into design requirements (Hows). In the QFD process this translation is facilitated by a relationship matrix .

The matrix is extended further to take account of engineering considerations and to include competitive benchmarking from both the customer's and engineer's view point in order that competitive opportunities can be identified.

Once the design requirements have been established in clear technical terms by several `What' to `How' iterations they are translated into specific part characteristics through the `What to How' process. Again this takes several iterations. These part characteristics are then translated into manufacturing process requirements, which are subsequently translated into specific production requirements .

The strength of QFD is that it brings a discipline to upstream quality planning by which direct customer requirements are taken account of in terms of product characteristics.

Taguchi's (Taguchi, 1987; Earley, 1988; Phadke, 1989) quality engineering approach emphasizes the importance of what he terms off-line quality control. In general terms off-line quality control relates to those initiatives which are taken prior to full scale manufacture in the design and planning stages of both product ...