Presentation2(QFD)DB

7/29/2019 Presentation2(QFD)DB

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Quality Function

Deployment(QFD)

DIPTENDU BASU

EXECUTIVE MBA (2012-14)PRN NO - 001


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Technical Story

Imagine that two engineers within the same

company are working on two different components

of a car sunroof simultaneously but separately.

The insulation and sealing engineer develops anew seal that will keep out rain, even during

blinding rainstorm .

The handles, knobs, and levers engineer is

working on a simpler lever that will make the roof

easier to open.


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Technical Story-cont. The new lever is tested and works well with the old seal.

Neither engineer is aware of the activities of the other .As itturns out, the combination of heavier roof (due to theincreased insulation) and lighter lever means that the drivercan no longer open the sunroof with one hand

Hopefully, the problem will be detected in prototype testingbefore the car is put into production. At that point, one orboth components will need to be redesigned. Otherwise,cars already produced will need to be reworked and carsalready sold will have to be recalled. None of thesealternatives is pleasant and they all involve considerablecost.

Could such problems be avoided if engineers worked inteams and shared information? Probably not! Even in design

teams, there is no guarantee that all decisions will becoordinated.


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Technical Story-cont.

A formal method is thus needed for making sure thateveryone working on a design project knows the designobjectives and aware of the interrelationships of thevarious parts of the design.

Similar communications are needed between the customer

and marketing, between marketing and engineering,between engineering and production, and betweenproduction and the worker

In a nutshell, a structured process is needed that willtranslate the voice of the customer to technicalrequirements at every stage of design and manufacture.

Such a process is called Quality Function Deployment.


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QFD-A Brief History

Originally developed in Japan in the late1960s by

-Dr Shigeru Mizuno

-Yoji Akao

Now widely used not only in Japan but inEurope and the US

This was in response to the growing success ofthe Japanese industry during the 1970s


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QFD-Definition

A planning tool used to fulfill customer

expectations

A tool used to translate customer requirementsto engineering specifications

Is a link between customers-design engineers-competitors-manufacturing


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Definition-cont.

A structured process for planning the design of a

new product or service or for redesigning an

existing one. It emphasizes thoroughly

understanding what the customer wants or needs.Then those customer wants are translated into

characteristics of the product or service. Finally,

those characteristics are translated into details

about the processes within the organization thatwill generate the product or service.


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QFD-PURPOSE

Regarded as an important tool to:

-improve quality

-reduce manufacturing costs

-increase organization capabilities

-to make the organization more competitive

- develop products that better fulfills users

needs


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Benefits of QFD

Improves customer satisfaction

- defines requirements into basic needs- fewer customer complaints

Reduces implementation time

- reduction in design changes- expensive corrections and redesigns are eliminated

Promotes teamwork

-inputs are required from all facets of an organization

Provides documentation

-database serves as a valuable source for future designs Increases in market share


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QFD-Some Problems

Misinterpretation-mistaking product characteristics for customer requirements

-often the answers given by customers are difficult to classify as needs

Time and resource

-often seen as additional workload

-costly, the planning stage may take longer

Constraints

-investment in training & market research and use of key functionalrepresentatives

-makes high demands on already stretched personnel resources


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QFD Process

Phase I- Product Planning

Phase II- Part Development

Phase III- Process Planning

Phase IV- Production Planning

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A Series of Connected QFD

Houses

Custo

mer

require

ments

Productplanning

Product

characteristics

A-1

Product

characteristics

Parts

development

Part

characteristics

A-2

Part

characteristics

Processplanning

Process

characteristics

A-3

Process

characteristics

OperatingPlanning

Operations

A-4


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Phase I- Product Planning

(House of Quality)

Translate customer requirement into product

technical requirements to meet their needs.

Links user requirements to product

attributes.

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Phase II- Part Development

Translate technical requirements to key part

characteristics or systems.

Subsystems broken down into critical part

characteristics

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Phase III- Process Planning

Identify key process operations necessary to

achieve key part characteristics.

Relates single subsystems with production

processes (critical step)

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Phase IV- Production Planning

(Process Control)

Establish process control plans, maintenance

plans, training plans to control operations.

Define quality control steps to follow.

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QFD

Goal =

The house of quality is used as a tool tomeet customer demands and understandcustomer requirements

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EXAMPLE

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MAKE A QFD FOR AN

ELECTRIC IRON


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House of Quality

Trade-off matrix

Design characteristics

Customer

requirements

Target values

Relationship

matrix

Competitive

assessment

Importance

1 2

3

4

5

6


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Competitive Assessment

of Customer Requirements

Irons

well

Easyand

safetouse

Competitive Assessment

Customer Requirements 1 2 3 4 5

Presses quickly 9 B A X

Removes wrinkles 8 AB XDoesnt stick to fabric 6 X BA

Provides enough steam 8 AB X

Doesnt spot fabric 6 X AB

Doesnt scorch fabric 9 A XB

Heats quickly 6 X B AAutomatic shut-off 3 ABX

Quick cool-down 3 X A B

Doesnt break when dropped 5 AB X

Doesnt burn when touched 5 AB X

Not too heavy 8 X A B

F


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Energyneededtopress

Weightofiron

Sizeofsoleplate

Thicknessof

soleplate

Materialused

insoleplate

Numberofho

les

Sizeofholes

Flowofwaterfromholes

Timerequiredtoreach450F

Timetogofrom450to100

Protectiveco

verforsoleplate

Automaticsh

utoff

Customer Requirements

Presses quickly - - + + + -

Removes wrinkles + + + + +

Doesnt stick to fabric - + + + +

Provides enough steam + + + +

Doesnt spot fabric + - - -

Doesnt scorch fabric + + + - +

Heats quickly - - + -

Automatic shut-off +

Quick cool-down - - + +

Doesnt break when dropped + + + +

Doesnt burn when touched + + + +

Not too heavy + - - - + -

Irons

well

Easyand

safetouse

From

Customer

Requirements

to DesignCharacteristics


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SS = Silverstone

MG = Mirorrglide

T = Titanium

Completed House of Quality


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THANK YOU

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