This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
The Application of Axiomatic Design in DFSS: A New Paradigm
DFSS is a philosophy and a methodology that provides businesses with perspectives and tools to achieve new levels of performance both in service and product industries. Axiomatic design technology is a process to improve the quality and performance of complex system and product development. This process provides a systematic and logical methodology for deriving, documenting and optimizing designs. Design architectures resulting from axiomatic analysis provide frameworks for implementation planning, risk assessment, risk mitigation and robust design analysis. This session will give you practical insight into Axiomatic Design employment in Design for Six Sigma on the technical and deployment fronts. The key areas of focus are:
A high-level overview of Axiomatic DesignAxiomatic Design innovation and its synergy with TRIZA principle-based Design for Six Sigma using Axiomatic Design technologyDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
The Application of Axiomatic Design in DFSS: A New Paradigm
The key areas of focus are:A high-level overview of Axiomatic DesignA principle-based Design for Six Sigma using Axiomatic Design technologyAxiomatic Design innovation and its synergy with TRIZDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
The Application of Axiomatic Design in DFSS: A New Paradigm
The key areas of focus are:A high-level overview of Axiomatic DesignA principle-based Design for Six Sigma using Axiomatic Design technologyAxiomatic Design innovation and its synergy with TRIZDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
Problems With Coupled DesignLow quality and reliability in particular with bigger design matrices and several hierarchal levels
Customer usage and manufacturing variations (noise factors) usually win with coupled designs…Usually due to the ignorance of design mappings and coupling vulnerability.Optimization and variability reduction (even with aggressive Six Sigma) is at best a trade-off among functional requirements to achieve reasonable overall design…Remember the EXCEL Example.
Inherently a “weak” design because of conflicting objective due to design parameters. By definition, functions are independent to each others and only a poor selection of DPs creates dependencies.
Design improvement should be directed to “Uncouple” or “Decouple” the design where optimization of a function will not affect other functions.
The Independence AxiomA good design comprises of Design Parameters (DPs) that maintain the independence of functional requirements (FRs)Also between DPs and PVs.
The Application of Axiomatic Design in DFSS: A New Paradigm
The key areas of focus are:A high-level overview of Axiomatic DesignA principle-based Design for Six Sigma using Axiomatic Design technologyAxiomatic Design innovation and its synergy with TRIZDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
Principle-based DFSSIdentification of key design principles as the foundation of the DFSS process.
Customer (user) driven design requirementsEstablish knowledge of performance variationMaximize independenceMinimize complexityConceptual superiorityOptimize function in the presence of noiseVerify that optimization translates to meeting user requirements
The Application of Axiomatic Design in DFSS: A New Paradigm
The key areas of focus are:A high-level overview of Axiomatic DesignA principle-based Design for Six Sigma using Axiomatic Design technologyAxiomatic Design innovation and its synergy with TRIZDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
The Application of Axiomatic Design in DFSS: A New Paradigm
The key areas of focus are:A high-level overview of Axiomatic DesignA principle-based Design for Six Sigma using Axiomatic Design technologyAxiomatic Design innovation and its synergy with TRIZDesign for Lean Six Sigma: An axiomatic design application to cellular manufacturing
Objective: transform traditional production system from process orientation to cellular orientation using DFSS principle (3): Maximize Independence. A feedback mechanism for continuous improvement is also suggested for evaluating and improving the cellular design against pre-selected performance criteria The needs of plant are to get flexibility ∆:
More product varietySmaller batch sizesHighest quality and more frequent deliveriesLower production costSpeed and ability to respond to changing needs
Design of cellular manufacturing system based on AD principles
Design of cellular manufacturing system based on AD principles
Implementation of cellular design
Implementation of cellular design
Performance evaluation of key metrics
Performance evaluation of key metrics
Targets met?
AD based continuous improvement process
AD based continuous improvement process
Improvement of the cellular system
Improvement of the cellular system
Set improved targetsSet improved targets
No
Yes
Preliminary Design Stage
Preliminary Design Stage
Design of cellular manufacturing system based on AD principles
Design of cellular manufacturing system based on DFSS principles
Hierarchical Level 3 Analysis: For FR1(=Classify and group products/ components for simple material flow) with DP1 (=Procedure for defining product families) in mind:
FR11 = Determine high volume products/ components to group
FR12 = Determine operations and machine types for producing each product family
FR13 = Form product families
FR14 = Determine final number of machine groups
DP11 = Product-Quantity Pareto Analysis
DP12 = Machine-Component Incidence Matrix
DP13 = Products grouping techniques
DP14 = Cost Analysis and economic justification techniques
In Plain English…The sequence of activities revealed by the design matrix is as
follows:1.Establish the high volume products through Product-Quantity
(Pareto) analysis (DP11), then…2.Group similar products (in terms of their process
requirements) into product families (DP12), then…There are several algorithmic procedures to accomplish this task. Most of them use the Machine-Component Incidence Matrix. These algorithms swap rows and the columns of this matrix until suitable block-diagonal sub-matrices or near block-diagonal sub-matrices are obtained. The products that fall into the same sub-matrix are candidates to be allocated to a potential cell.
3.Decide on how many of these cells to implement based on economic justification principles (DP13), then…
4.Perform cost benefit analyses on each potential cell formation. In this process, each candidate cell’s contribution to the company’s bottom line in terms of productivity, lead time and profitability together with return on investment are calculated.Those cells that satisfy the company internal rate of return arerecommended for formation (DP14) .
Hierarchical Level 3 Analysis: For FR2(=Define production strategy based on product specifications with DP2 (=Procedure for selecting production strategy) in mind:
The sequence revealed by the design matrix is as follows:
1.Establish the master process based on product specifications (DP21), then…
2.Determine the production resources (DP22), then…
3.Complete the resource selection (DP23), then…
4.The education and training requirements of the workers can be established (DP24).
For ensuring the full participation of workers in the education and training activities followed by transition to cellular manufacturing, appropriate gain sharing programs must be established and announced to the workers for strong buy in.