Day 2:

Design For Quality and Reliability

 Design & Quality?
• Design is the translation of customer requirements into
a form that is fit for use.
• Quality means meeting the requirements. The totality
of features and characteristics of a product that bear its
ability to satisfy the stated or implied needs.
– Stated needs: Good quality ball point pen with metal body
– Implied needs: Ability to write
• Quality of design is a measure of how well the product
is designed to achieve its stated purpose.
 Definitions of Quality?

• Degree of excellence
• Conformance requirements
• Fitness for use
• Fitness for purpose
• Freedom from defects
• Customer delight
 Dimensions of Quality

• Quality by design
• Quality by conformance
• Quality by performance
 Quality by Design (QbD)
• It means the intensions of designers to include or exclude
features in a product or service.
• i.e. The degree to which the quality characteristics are
embedded into the product or service.
• Example:
– Ford vs. BMW – both are made for fit for use, but
designed for different set of customers
– Economy vs. 5* Hotel – All hotels can provide a place to
sleep, but many features of design show its quality like
comfort, luxury, ambience etc.
 Quality by Conformance (QbC)
• It means how well the product or service meets the
specification determined by designers.
• QbC is directly measurable, though it may not be directly
associated with consumers’ perception on quality.
• Example:
– Hotel industry – if the promised service time after
taking an order is 15-20mins, but delivery takes
30minutes, it means that it has poor quality of
conform.
 Quality by Performance (QbP)
• Quality of performance is associated with the reliability of
the product or service. It means the product, part or
system is performing its intended function under a
prescribed set of conditions.
• It extents the robustness of a product so it increases the
repeated sales, reflects on the products image. If it is poor,
it will create a negative impact about the product as well
as company.
• Example:
– Antivirus software
 Design, Quality and The Requirements
• Specifications are the most important to achieve the required quality
of a design/product.
• Quality of design goes beyond the product design and its ability to
meet the customer requirements.
• Correctness of the actual design process has a deep influence on the
quality performance of any organization.
• When DfQ, there are three important terms we should
understand:
– Research is the discovery of novel techniques, ideas, information systems –
market research should be clearly carried out.
– Development of the improvement of the existing systems, techniques or ideas.
– Commitment to quality – maintain the good relationships between various
groups and functional areas throughout the design process.
 Why DfQ is important?
• The DFQ process allows the engineer to identify, plan for
and manage factors that impact the robustness and
reliability of the products in the design process.
• DFQ reduces or eliminates the cost of quality that can be
envisaged as the cost incurred in the inspection and
rework, in the procurement of replacement materials.
• Appropriate DFQ procedure can also avoid defects and
errors, scrap, degradation of factory/machine capacity,
re-qualifications/re-certifications expenses, and overhead
demands.
 Why DfQ is important?
• Improved and consistent quality of parts provide better
appeal to the customers that obviously lead to greater
stability of the manufacturing shops and can create
greater amount of opportunities.
• Example: Rolls-Royce
– The reported cost of non-quality is 400M
– 40000 concessions and deviations
– 12000 internal quality escapes
– 60% of delivery failures are caused by quality issues
 Problems with relying on inspection
Carryout 100% inspection on the following paragraph by counting the number of “f”s:

Five fearful fellows fought a frightful on Friday

afternoon in Fife. Four of the five fearful fellows fought
for fifteen minutes, but one of the fellows found a fist in
his face in the first five minutes which finished him off.
Finally four fat officers finished the fight, and the five
fearful fellows faced the full force of the law
100% inspection is never 100% effective ….

Therefore we must focus on the PREVENTION of non-conformance

 Product & Process Readiness

Design &
Pre-
Planning Concept Development Production
Production
generation

• Project kick-off • Product concept • Initial product • Product & • Production rate
• Requirements selection release Production ready

Measurement
DFSS & Zero- SPC – Process
QFD FMEA Control Plan System
Defects control
Analysis
 Planning & Requirements Identification
• If quality design is taking care of all aspects of the customer
requirements, including cost, production, safety and easy use,
and maintainability of products and services, then designing
must take place in all aspects of:
– Identifying the need (including the need for change);
– Developing that which satisfies the need;
– Checking the conformance to the need;
– Ensuring that the need is satisfied.
• Specification and standards:
– Strong relationship between standardization and specification.
– Standardization does not guarantee that the best design or
specification is selected.
 Specifications
• Specification conveys the customer requirements to the
supplier to allow the product or service to be designed,
engineered, produced or operated using conventional or
stipulated equipment, techniques and technology.
• Basic requirements of a specification:
– Performance requirements of the product or service;
– Parameters like size/dimensions
– Materials to be used
– Method of production or operations
– Inspection/testing/checking requirements
– References to the other documents
 DfQ tools
• Success at continual quality improvement requires an integrated
‘company-wide approach’ and all parts of an organization must
cooperate to produce products that are fully satisfy the customer’s
needs.
• To improve the design of a product a number of tools available and
are collectively known as Quality Function Deployment (QFD), used
to address various aspects of the design process.
1. Affinity diagram, 2. Interrelationship digraph
3. Tree diagram, 4. Matrix diagrams or charts
5. Matrix data analysis, 6. Process decision program chart
7. Arrow diagram, 8. Scatter diagram
9. Cause and effect diagram, 10. Histogram
 Affinity Diagram
• The affinity diagram is a business tool used to organize ideas
and data.

• An Affinity Diagram is a tool that gathers large amounts of

ideas, opinions, issues and organizes them into groupings based
on their natural relationships

Process
• Record each idea on cards or notes
• Look for ideas that seem to be related
• Sort cards into groups until all cards have been used.

Note:
If less than 15 items of information have been identified, then
Creating an Affinity Diagram
Step 1 - Generate ideas
Step 2 - Display ideas
Step 3 - Sort ideas into groups
Step 4 - Create header cards
Step 5 - Draw finished diagram
Step 4: Create Header cards
 Critical to Quality (CTQ) Trees
Used to translate broad customer needs into specific, actionable
and measurable performance requirements

Step 1: Identify Critical Needs of the customers

Step 2: Identify Quality Drivers
Step 3: Identify Performance Requirements
 Cause- and- Effect Diagram
• It helps to determine the root causes of a problem
using a structured approach.

• It encourages group participation and utilizes group

knowledge of the process.

• Easy-to-read format

• It indicates possible causes of variation in a process.

 Product/Manufacturing
Man

Machine Methods
Five Key
Sources of
+ Environment
Variation

Materials Measurement

Use cause and effect diagram to single out variation sources within the
“5M’s + E”

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 Transactional/Service
People

Policies Procedures
Five Key
Sources of
Variation
+ Environment

Place Measurement

Use cause and effect diagram to single out variation sources within the
“4P’s + M&E”

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 Causes Effect

Main Category

Problem

Cause

Root Cause

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Reference: International Journal of Quality & Reliability Management Volume
12 issue 4

“Implementing a quality maintenance system in a military organization”

 Scatter Plots
• The Scatter plot is another problem analysis tool.
• Scatter plots are also called correlation charts.
• A Scatter plot is used to uncover possible cause-and-effect relationships.
• It is constructed by plotting two variables against one another on a pair
of axes.
• A Scatter plot cannot prove that one variable causes another, but it does
show how a pair of variables is related and the strength of that
relationship.

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5/1/2022 11:39 AM B. Shahul Hamid Khan, IIITDM 32
 Scatter plot of tool wear Vs Depth of cut

5/1/2022 11:39 AM B. Shahul Hamid Khan, IIITDM 33

 Scatter Diagram

5/1/2022 11:39 AM B. Shahul Hamid Khan, IIITDM 34

 Quality Function Deployment (QFD)
• QFD is a structured approach to defining customer needs
or requirements and translating them into specific plans
to produce products to meet those needs.
• QFD matrix is a natural choice for representing the
transfer function.
• QFD process is probably the most effective methodology
available for capturing and responding to the “voice of
the customer”.
• QFD was originally created by two Japanese professors
back in the 1960’s (Drs. Yoji Akao and Shigeru Mizuno).
• Japanese name of QFD is Hin-shitsu Ki-no Ten-kai.
Quality Function Deployment (QFD)
Step 1: Customer Requirements
Step 1: Customer Requirements
Step 1: Customer Requirements
Step 1: Customer Requirements
Step 1: Customer Requirements
Step 1: Customer Requirements
Example
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix
Step 2: Planning Matrix