Design for quality: Quality Function Deployment, life-cycle management,

FMECA (Failure Mode, Effects, and Criticality Analysis), and quality audit

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1. Quality must be designed into the product, not inspected into it. Quality can be defined
as meeting customer needs and providing superior value. This focus on satisfying the
customer's needs places an emphasis on techniques such as Quality Function
Deployment to help understand those needs and plan a product to provide superior
value. Voice of customers must be heard and captured.
2. Quality Function Deployment (QFD) is a structured approach to defining customer
needs or requirements and translating them into specific plans to produce products to
meet those needs. The "voice of the customer" is the term to describe these stated and
unstated customer needs or requirements. The voice of the customer is captured in a
variety of ways: direct discussion or interviews, surveys, focus groups, customer
specifications, observation, warranty data, field reports, etc. This understanding of the
customer needs is then summarized in a product planning matrix or "house of quality".
These matrices are used to translate higher level "what's" or needs into lower level
"how's" - product requirements or technical characteristics to satisfy these needs.
3. It is important to remember that there is no one monolithic voice of the customer.
Customer voices are diverse. In consumer markets, there are a variety of different
needs. Even within one buying unit, there are multiple customer voices (e.g., children
versus parents). This applies to industrial and government markets as well. There are
even multiple customer voices within a single organization: the voice of the procuring
organization, the voice of the user, and the voice of the supporting or maintenance
organization. These diverse voices must be considered, reconciled and balanced to
develop a truly successful product. One technique to accomplish this is to use multiple
columns for different priority ratings associated with each customer voice in the
product planning matrix.
Source: Kenneth Crow (2002) 2
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QFD for Translating Customer to System Requirements as well as Prioritizing

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Source: Porter (1985)

Design for Life Cycles

Design and Production and Use, Maintenance, Retirement and

Development Construction and Support Disposal

Acquisition Phase (Design Utilization Phase

or Acquisition)
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Life-cycle Design and Management:
1. Design/production (e.g., cars, tanks, airplanes, etc.) and
2. Design/construction (e.g., airport, expressway, etc.)

Acquisition Utilization

Need and Preliminary Production Product use or

conceptual and detail and utilization and
design design construction phase-out
Process and other Process utilization
related-elements for production
configuration design and operation
Product and process support Product support
configuration design and for maintenance
development (implementation) and repair

Implications on cost incurred by producers as well as burden on

customers– for the bold lines
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Key words for Design for Quality: commonality, interchange-ability, logistics footprints, etc.

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Life-cycle Design Consideration
The HMMWV is equipped with a high performance diesel engine,
automatic transmission and four wheel drive that is air transportable
and droppable from a variety of aircraft. It is supported using the
current logistics and maintenance structure established for Army
wheeled vehicles.

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 The 777 Family: Flexibility in Capacity and Range
(Commonality and Standards)
450

400
777-300 777-300ER
350
777-200 777-200ER
300
Three-class
seats

250

777-200LR
200

150
North Pacific + Europe-Asia
North Atlantic U.S.-Asia
100
4 5 6 7 8 9 10 11
(8) (10) (12) (14) (16) (18)
Range, 1,000 nmi (1,000 km)

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One of the
reasons the
Boeing 737 is so
popular with low-
fare airlines is its
ease of
maintenance. As
shown here, the
airplane sits low
to the ground,
allowing
maintenance
crews to easily
perform routine
maintenance on
the engines
(maintainability).

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The A380 will have the widest cabin in the world and a larger cockpit, but pilots
transferring from the new generation Airbus family will easily familiarize themselves with
it. For example the time for transition training from the A330/A340 Family is expected to be
considerably less than the 25 days needed for transition training without commonality.

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Source: www.roymech.co.uk/.../ARM/Reliability.html
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Group Assignment 5: Boeing 787 News
Boeing has proved to regulators that the 787 Dreamliner’s handling qualities are similar to
the 777 — a key milestone toward winning type commonality approval between the two
models for crew qualification
1. Examine the recent news about the groundings of B787 and analyze how Boeing and
the airlines (especially ANA and Japan Airlines) have handled the situations while
inspections were made on an aircraft’s technical problems
2. Explain how Boeing attempts to minimize its customer’s business risk as part of quality
assurance

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The U.S. Marine Corps wants a short takeoff and vertical landing or STOVL aircraft to replace
its AV-8B Harrier and F/A-18 Hornet so it can transition to an all-STOVL strike force early in
the 21st century. The U.K. Royal Navy and Royal Air Force require a STOVL aircraft to replace
their aging Sea Harrier and GR.7, respectively. The Marine Corps is scheduled to acquire
609, while the U. K. Royal Navy will purchase 60 and the Royal Air Force plan to buy 90
aircraft. The short takeoff and vertical landing or STOVL variant of the Boeing JSF for the U.S.
Marine Corps and U.K. Royal Navy/Air Force employs a direct lift system for short takeoffs
and vertical landings with uncompromised up-and-away performance.

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1. Aircraft Acquisition: The U.S. Navy began replacing its aging fleet
of 29 C-9B Skytrain aircraft in 1997 and has ordered nine C-40s to
date. The U.S. Naval Reserve will operate and maintain the
aircraft.
2. The C-40A is a Boeing 737-700 aircraft certified to operate in three
configurations: (1) all-passenger configuration (121 passengers),
(2) all-cargo configuration (up to eight pallets), and (3)
combination, or "combi," configuration (up to three cargo pallets
and 70 passengers).
3. The C-40A already is setting new standards in performance, low-
cost operations and reliability. The 737-700 builds on strengths
that have made the 737 the world's most successful commercial
airliner. With its superior range and performance, 777-type flight
deck, updated avionics and fuel-efficient engines, the 737-700
aircraft increases the Navy's capability to meet its rapid airlift
requirements
4. The Navy's C-40A fleet takes full advantage of the 737 aircraft's
lifetime support services, including its comprehensive field
service and spares distribution network.
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Japan Air Self-Defense Force (E-767)

Boeing 767 Acquisition

1. Military: Versions of the 767 serve
prominently in a number of military
applications.
2. The Boeing KC-767 is a military aerial
refueling and strategic transport aircraft
developed from the Boeing 767-200ER
3. The Boeing E-767 is an Airborne Early
Warning and Control aircraft. It was
designed in response to the Japan Air
Self-Defense Force's requirements, and
is essentially the E-3 Sentry mission
package on a Boeing 767-200 platform
Japan Air Self-Defense Force (KC-767) 40
Boeing 767 (Commercial Airplane)
With more than 900 aircrafts built

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 M1A2: Upgraded Version of M1-A1

Maximum Speed: 42 mph (Governed)

Cruising Range: 265 Miles
Cross Country Speed: 30 mph
Obstacle Crossing: 42 Inches
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Key points:
Because the Wolverine is essentially an M1A2 tank with bridgelaying
gear instead of a turret it shares virtually all of the parent vehicle's speed,
mobility, survivability, and automotive components. This interoperability
was a key design factor in the Wolverine's development. The Wolverine
also features an advanced communications package designed to keep it
in contact with local field commanders. However, the vehicle itself is
completely unarmed

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 M104 WOLVERINE HEAVY ASSAULT BRIDGE
PERFORMANCE PARAMETERS:
Mobility Capabilities Equivalent or Compatibility to Abrams Main Battle Tank
(MBT),
Fully Redundant Launch Controls in Both Crew Stations,
Redundant Hydraulic and Electrical Power Source,
Maximum speed: 42 mph (governed),
Launch time: Less than 5 min and Recovery time: Less than 10 min,
Vertical obstacle: 42 inches,
Cruising range: 260-265 miles,
Gap Crossing Capability: 24 meters.

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Source: www.parkerscitech.com

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Life-cycle Design: Commonality, Interchangeability, Interoperability, and
Standards

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Key Components for DOD 5000.1 and 5000.2

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Design for Quality: Consideration into Life-cycle Support
 Customer-to-customer Chain

WHAT ? WHERE ? WHEN ? WHICH ? TO WHOM?

C C
O O
S S
T T
U U
COMPANY
M M
E E
R R

Design for Quality

Quality Audit

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Purposes of the audit:
1. To ensure that quality meets the expectation of customers
2. To ensure that quality compliances with existing standards and
regulations
3. To gain confidence from stakeholders in a supply chain– customers,
manufacturers, and suppliers
4. To show there exists a mechanism for quality assurance

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Source: www.iso9001implementationdocuments.info
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1. Quality audit is the process of systematic examination of a quality
system carried out by an internal or external quality auditor or an
audit team. It is an important part of organization's quality
management system and is a key element in the ISO quality system
standard, ISO 9001.
2. Quality audits are typically performed at predefined time intervals
and ensure that the institution has clearly defined internal system
monitoring procedures linked to effective action. This can help
determine if the organization complies with the defined quality
system processes and can involve procedural or results-based
assessment criteria.
3. With the upgrade of the ISO9000 series of standards from the 1994
to 2008 series, the focus of the audits has shifted from purely
procedural adherence towards measurement of the actual
effectiveness of the Quality Management System (QMS) and the
results that have been achieved through the implementation of a
QMS.
4. Other industries have applied quality audit such as hospitals,
airlines, airports, primary and secondary educations, hotels, etc.
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Source: www. en.wikipedia.org/wiki/Quality_audit
Internal Quality Audit: ISO 9001-2008

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