Quality by Design

Concept of Product Development Life Cycle, came in scene recently.

Concept of conducting conceptual thinking , product design and production planning all at one time.

Also known as- Concurrent Engg. Simultaneous Engg. Parallel Engg.

Tradional Approach

Known as Sequential Engg.

Whole process done in a sequence of small modules.

“throwing it over the wall” approach.

Sequential Engg.

PerformanceCostMarketabilityAestheticsManufacturabilityTestabilityServiceabilityQualityReliabilityAssembly

Parallel Engg. Approach

A team of specialists from different fields(Design, Engg. , Business) is made, which performs major functions of main process altogether.

Major functions of the main process done simultaneously, at the same time, to ensure producibility and customer satisfaction.

Parallel Engg.

Product Definition

Engineering

Manufact-uring

Suppliers

Managemnt

Customers

Design

Marketability

Manufacture -ability

Testability

Performance

Aesthetics

Service-ability

Reliability

Cost

Quality

Assembly

Verification

Prototype, Production,

Testing

Sequential vs. Parallel

1) Input

2) Flow of communication

3) Redesigning, Reprototyping, Reverification.

4) Time taken.

5) Problems occurred in later phases.

Product Developement Time Line

Sequential Engg.

Quality by Design

0 1 2 3 4 5 6 7 8 9 10

Definitions

Design

Verification

Prototype

Redesign

Reverification

Reprototype

Test Gen.

Manufacturing

Test

Teams Team includes developers from-

i. Marketingii. R & Diii. Designiv. Productionv. Testvi. Managementvii. Suppliers and Customers also, when/ if reqd.

Commitment to project, not to functional dept’s.

Exchange of ideas- upstream & downstream.

Teams (contd.)

Better the interaction b/w team members , better the product design.

e.g. of a team-Rayovac formed a quality by design

team composed of people from design , engg. , sales , quality , manufacturing, purchasing, finance and suppliers to design a new fluorescent camping light. Using this approach, they're able to reduce the usual product development time from 3 yrs to 1 yr.

Benefits

Faster Product development.(by 30%-70%)Better Quality.(200%-600%)Fewer later Engg. changes.(less by 65%-90%)Increased Productivity.Lesser time to take product to market.(up to 90%)More profits.Less Reworks.

(By National Institute of Standards and Technology)

Misconceptions & Pitfalls

Some Misconceptions-Quality by Design is a sure way to success.It is “design & production” simultaneously.It is a “Inspection techniques of TQM”.

Some Pitfalls to Avoid-Team members should be assigned to functional

dept.’s, but their 1st loyalty should lie for Quality by Design team.

Avoid changing product definition during specifications phase.

Aoid using tight tolerances to obtain one pass design.

Thank You

!!!