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Engineering Process Improvement Model

Engineering Model is a collection of process elements and principles that can be


used as a pattern for Engineering process development and a criterial against
which a process can be defined.
ISO 9001: Requirements

Quality Management
Project Needs/Conceptual Study
Industrial Standards
Project Management Plan
Design Development
Design Validation
Cost Management

Engineering Approaches
Engineering Approach is a system of tools that is been used to guide problem
solving, management and other engineering procedures.
Total Quality Management: It is a way of managing people and business
processes to ensure customer satisfaction at every stage of the engineering
process.
Customer
focus
All Staff
participati
Planning
on
Process

TQM

Process
Improveme
nt

Project
Manageme
nt

Engineering Approaches
Lean Engineering: A process of eliminating the non-value added waste in the
product development process. In the lean engineering, three elements must be
integrated to create a valuable product and process development systems - IPPD
TOOL
S
AND
TECH

Lean Engineering Principle

LEAN
IPPD
ENGINEERI
NG
PROCESS

SKILLED
PEOPLE

Lean Engineering Process


Six Engineering Wastes:
Over- production- Analysis, report, tests not needed.
Inventory- Unfinished analysis, reports, test.
Unnecessary Movement- Stop and Go task. Working on too many projects at a time.
Waiting- Waiting for decisions or waiting for input.
Defective Outputs - Rework due to wrong requirements or input.
Unused employee creativity- Not engaging engineers in process improvements for engineering.

Product Development Lead Time


12

TIME vs PROCESS

10
8
6
4
2
0
Non-Value added
time(WASTE)
Column1

Product Development Lead Time


Value added time is a small percentage of the lead time.
Project cost savings focused on only Value Added process.
LEAN focuses on Non-Value Added process

Lean Engineering Tools


Engineers should work together as integrated Product Teams. They are responsible
for the development, analysis and decision making in the product design process.
Engineers should also be involve in about 80 percent or more in or real value-added
work.
Integrated digital tools reduce wastes of handoffs and waiting, and increase quality

Mechanical (3-D solids design tools)


Software development environments/Model-Based Engineering

Common parts / specifications / design reuse


Design for manufacturing and assembly (DFMA)
Dimensional/configuration/interface management
Testing (only OEM)
Product Lifecycle Management (PLM)software

Engineering Approaches
Six-Sigma Engineering (DMAIC): This is a process improvement methodology which
includes different stages integrated with one another to enhance the engineering design
process performance. This process help in eliminating defects in design process.
Define

Contro
l

Impro
ve

Measu
re

Analys
e

Six-Sigma Methodology
The methods used to describe Six-sigma application are divided into 5 phases:
Define Phase: The design phase sometimes called the design phase, is the phase
where the goals of the engineering improvement are clearly defined.
Parameters which vastly influence determine the enterprise goals in respect to quality
Critical to Quality (CTQ)
Voice of the Customers (VOC)
o Brain Storming

Measurement Phase: This phase involve the past data collected on CTQ. The mean
average of all the observations is stored in a date set, and this is useful in the process
capability index. Performance parameters.
Analyses Phase: In this phase a critical analyses is carried out to defined
performance goals, process baseline and variation identifications. Problem root cause

Six-Sigma Methodology
Improvement Phase: This phase is the step where creative solutions to existing
problems can be developed and tested using different techniques. It is about verification
and validation of recommendations.
Control Phase: This phase is to ensure a successful implementation of the team
recommendations so that long-term success will be achieved. The new and improved
process will be represented with a flow chart, and these new standard will become the
new standard operation procedures.

Project & Process Management De


cision Making Tree
Review
Review the
the key
key
Metric
Metric Control
Control
Chart
Chart

Investigate
Investigate
Special cause
Special
cause
and
and Stabilize
Stabilize
Process
Process

No

Is
Is the
the
process
process
Stable?
Stable?
Yes
Are
Are
results
results
Good
Good
Enough?
Enough?

Yes

Monitor
Monitor
Process
Process

No

Start
Start Process
Process
Improvement
Improvement

Define

Sponsor,
Sponsor,
Scope,
Scope, Process
Process
Map,
Map,
Stakeholders
Stakeholders

No

Measure
Operation
Operation definition,
definition,
Collect
Collect data
data

Has
Has Six
Six
Sigma
Sigma been
been
assigned?
assigned?

Yes

Analyse

Improve

Root
Root causes
causes and
and
Effect
Effect

Brain
Brain Storming,
Storming,
Test
Test results,
results,
Process
Process pattern
pattern

What
What
DMAIC step
DMAIC
step
Team
Team
Working
Working on
on

Control
Handoff
Handoff plan,
plan,
Audit
Audit plan,
plan,
Training
Training plan,
plan,
reaction
reaction plan.
plan.

Engineering Process Improvement

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