Designing Products and Processes with a Future 1

Designing Products and Processes with a Future 1

What does it take? l Involve the customer l Meet with the customer l Listen to customer l Educate the customer l Incorporate quality function deployment (QFD) l Design for robustness 2

What is a customer? n n n n The person who buys the product? The federal regulator? The consumer reporter? The marketing and sales department? Engineering? Manufacturing? Suppliers? 3

How do you hear the customer? Features Needs n Wants n Satisfaction n Perception n Quality ABOUT Value Importance Competitors Detractors 4

Product Design What the Customer wanted What Marketing described What Engineering designed Actually Manufactured 5

What is Design? ……A Decision Making Process Flexibility £ Idea generation £ Assessment of firm’s ability to carry out £ Customer Requirements £ Functional Specification £ Product Specifications £ Concept Generation £ Concept Selection £ Engineering Design £ Engineering Evaluation £ Prototype and Testing n Manufacturing Design Cost 6

Few Successes Number 2000 1500 1000 500 0 Ideas 1750 Market requiremen t 1000 Functional specification s 500 Design review, Testing, Introduction Product specificatio n 100 25 One succes s! Development Stage 7

QUALITY FUNCTION DEPLOYMENT n Quality Function Deployment ¨ Uses the voice of the customer to build a design tool: n House of quality QFD: An approach that integrates the “voice of the customer” into the product and service development process. 8

Quality Function Deployment n Identify customer wants n Identify how the good/service will satisfy customer wants n Relate customer wants to product hows n Identify relationships between the firm’s hows n Develop importance ratings n Evaluate competing products 9

House Of Quality Importance Product characteristics Customer requirements Relationship matrix

Idea Generation Stage Provides basis for entry into market n Sources of ideas n ¨ Market need (60 -80%); engineering & operations (20%); technology; competitors; inventions; employees n Follows from marketing strategy ¨ Identifies, defines, & selects best market opportunities 11

Customer Requirements Stage Identifies & positions key product benefits ¨ Stated in core benefits proposition (CBP) ¨ Example: Long lasting with more power (Sears’ Die Hard Battery) House of Quality Identifies detailed list of product attributes desired Product by customer Characteristics ¨ Focus groups or Customer 1 -on-1 interviews Requirements n n 12

Functional Specification Stage n n Defines product in terms of how the product would meet desired attributes Identifies product’s engineering characteristics ¨ Example: printer noise (d. B) Prioritizes engineering characteristics n May rate product compared to competitors’ House of Quality n Product Characteristics Customer Requirements 13

Product Specification Stage n n Determines how product will be made Gives product’s physical specifications ¨ Example: Dimensions, material etc. Defined by engineering House of Quality drawing Done often on computer Component Specifications ¨ Computer-Aided Design (CAD) Product Characteristics 14

Quality Function Deployment n Product design process using cross-functional teams ¨ Marketing, engineering, manufacturing Translates customer preferences into specific product characteristics n Involves creating 4 tabular ‘Matrices’ or ‘Houses’ n ¨ Breakdown product design into increasing levels of detail 15

To Build House of Quality n Identify customer wants n Identify how the good/service will satisfy customer wants. n Relate the customer’s wants to the product’s hows. n Develop importance ratings n Evaluate competing ideas and concepts Ultimately you choose the design Not the customer! 16

House of Quality Example You’ve been assigned temporarily to a QFD team. The goal of the team is to develop a new camera design. Build a House of Quality. © 1984 -1994 T/Maker Co. 17

House of Quality Example What the customer desires (‘wall’) Customer Importance Requirements Light weight Easy to use Reliable Target Values 18

House of Quality Example Average customer importance rating Customer Requirements Importance Light weight Easy to use Reliable 3 2 1 Target Values 19

House of Quality Example Choose engineering characteristics to satisfy the customer requirements Customer Aluminum Steel Requirements Importance Parts Light weight Easy to use Reliable Auto Focus Auto Exposure 3 2 1 Target Values 20

House of Quality Example Relationship between customer attributes & engineering characteristics (‘rooms’) Customer Aluminum Steel Requirements Importance Parts Light weight Easy to use Reliable Target Values 3 2 1 5 2 4 19 8 14 Auto Focus Auto Exposure 8 5 21 7 3 17 21

QFD Cascades 22

Sample House of Quality Adaptation of Piano Pedals for an Adult Todd Krzycki 23

Project Description n The Client has Multiple Sclerosis (MS) which has taken her ability to use her right leg and more specifically for this project her right foot. We will design a pedal adaptation to utilize the Una Corda and Damper pedals with her left foot with out making her strain to reach the right pedal. Todd Krzycki 24

Project Objectives Allow the client to use the Damper pedal with minimal effort. n Make a lightweight and small adaptive device to make the right pedal accessible. n Design a device that can be transported easily from home to school and back. n Avoid any sounds that could detract from the piano. n Todd Krzycki 25

Apparatus Usage • The apparatus is going to be used by the left foot of the client. • Using hands or arms to activate the pedals is not feasible because that would restrict the clients playing ability. • Using your head or chin to activate the pedals is an option but it would make the apparatus large and hard to transport. 26

Electric Apparatus Jeff Adams 27

Electric Apparatus Pros Cons • Easy to push the pedals down. The electric components will do the work that would have been required by the client. • Electric components are costly making the over all cost of the project high. • Compact. Electric components are small and can be made to fit in a small area. • Apparatus would fit smoothly between and around the piano pedals. • Safety concerns with electricity in the apparatus, as well as chemical concerns if batteries are used. • Harder to move electric components around to make it adaptable to multiple pianos. Jeff Adams 28

Mechanical Apparatus Jeff Adams 29

Mechanical Apparatus Jeff Adams 30

Mechanical Apparatus Jeff Adams 31

Mechanical Apparatus Jeff Adams 32

Mechanical Apparatus Pros Cons • The components that go into a mechanical system are cheap since the machining cost are donated by UT. • A mechanical system will not allow play of the Damper as well as the Una Corda pedal with our clients limitations. • Reliable. You do not have to worry about a battery dying or have to find plug to power the apparatus. • It would have to be larger to allow for all the transfers of motion in the system. • There is more feeling in the operations so it is easier to play the damper pedal correctly. • Light weight since light weight materials can be used and heavy batteries are not needed. • The forces used to depress the pedals would have to be solely supplied by the client. This may become a concern if the client’s condition worsens and they lose more strength in their left foot. Jeff Adams 33

Electric/Mechanical Apparatus 34

Electric/Mechanical Apparatus 35

Electric/Mechanical Apparatus 36

Electric/Mechanical Apparatus Pros Cons • The Una Corda can be held down electrically allowing the client use of their left foot to use the damper pedal. • Electric components are costly making the cost of the over all project higher. • Having some electric components makes it easier to use the fixture in a range of pianos. • Safety concerns with electricity in the apparatus, as well as chemical concerns if batteries are used. • By having one electric component instead of two will use less power making the user less reliant on large batteries. • Harder to move electric components around to make it adaptable to multiple pianos. • Having the damper pedal controlled by mechanical means allows for more precise playing of the piano. • Electrical components could cause noise that would distract from the sound of the piano. • If no power supply is available the majority of the functionality of the apparatus would still be intact. • Relying on electricity for part of the design is a concern of the client. 37

House of Quality Importance Electrical Light Weight 8 8 4 6 Size 7 6 4 5 Universal design 8 8 4 7 Damper is primary pedal 9 4 8 8 10 6 8 7 Tactile Response 8 1 10 10 Cost 6 4 7 6 Noise 9 4 6 5 334 420 442 Safety Mechanical Electrical/ Mech. 38

House of Quality Importance Solenoids Motors Hydraulics/Pneumatics Light Weight 8 8 2 1 Size 7 9 6 5 Universal design 8 8 6 2 Damper is primary pedal 9 5 5 5 10 9 7 5 Tactile Response 8 5 5 5 Cost 6 4 6 8 Noise 9 9 6 6 471 351 296 Safety 39

ROBUST DESIGN Design that results in products or services that can function over a broad range of conditions 40

What does Robust Design mean? n n n Plan for variability Assess your capabilities Design for manufacturing Reduce costs Practice! 41

Good Luck with your designs! 42