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Design for Quality:
Achieving 0
Rejection – A
Reality




          Natarajan R
              Director
            EGS India
Agenda

•   Introduction to Design For Quality – DFQ
•   Checklist for DFQ
•   Dimensional Management Techniques
•   Predicting Assembly Build
•   Automating Inspection Process
•   Summary




                                      www.egs.co.in
                                      www.egsindia.com
Introduction to DFQ

•   What Tolerance to allocate?
•   How will the tolerances affect function?
•   Will there be any assembly issues?
•   What will be the PPM estimates?
•   Is it really necessary to tighten tolerances?
•   Have I chosen the right tolerance?
•   Am I responsible for increasing the product
    Cost?


                                         www.egs.co.in
                                         www.egsindia.com
Did You Know?

Only about 60% of new products launched are
actually a success and that for every seven new
product ideas, only four make it to development
— and then only one succeeds.
  Source: Winning at New Products: Accelerating the
    Process from Idea to Launch - Robert G. Cooper




                                         www.egs.co.in
                                         www.egsindia.com
DFQ: Definition of Paradigm

•   Superior Functionality
•   Best Fit
•   Least Rejections
•   Highest Customer Satisfaction
•   Consistent Performance




                                    www.egs.co.in
                                    www.egsindia.com
Quality Issues

• Parts not aligning well for a perfect Fit
• Vibration & Noise due to moving parts
• Inconsistent Life & Performance under
  Controlled Testing
• Unpredictable Field Failures




                                        www.egs.co.in
                                        www.egsindia.com
Improper Fit




               www.egs.co.in
               www.egsindia.com
Vibration - Effects




                      www.egs.co.in
                      www.egsindia.com
Vibration & Noise




                    www.egs.co.in
                    www.egsindia.com
Field Failures




                 www.egs.co.in
                 www.egsindia.com
Six Sigma Approach




                     www.egs.co.in
                     www.egsindia.com
Design for Six Sigma (DFSS)

• Objective is to Understand the Root
  Cause and Eliminate Defects
• Maximize Return on Investment
• Incorporate Processes for
  Continuous Improvement
• Enables Gap Analysis of entire
  Product Development System
• Addresses Voice of Customer (VOC)



                                    www.egs.co.in
                                    www.egsindia.com
5 Steps in DFSS

• Plan—enable the team to succeed with the
  project by mapping all vital steps
• Identify—hear the voice of the customer to
  select the best product concept
• Design—build a thorough knowledge base about
  the product and its processes
• Optimize—achieve a balance of quality, cost, and
  time to market
• Validate—demonstrate with data that the voice
  of the customer has been heard and that
  customer expectations have been satisfied
                                     www.egs.co.in
                                     www.egsindia.com
DFSS – Another Perspective

• Define—determine the project goals and the
  requirements of customers (external and internal)
• Measure—assess customer needs and
  specifications
• Analyze—examine process options to meet
  customer requirements
• Design—develop the process to meet the
  customer requirements
• Verify—check the design to ensure that it’s
  meeting customer requirements

                                       www.egs.co.in
                                       www.egsindia.com
SS Vs DFSS

• DMAIC is more focused on reacting, on detecting
  and resolving problems, while DFSS tends to be
  more proactive, a means of preventing
  problems.
• DMAIC is for products or services that the
  organization offers currently; DFSS is for the
  design of new products or services and
  processes.
• DMAIC is based on manufacturing or
  transactional processes and DFSS is focused on
  marketing, R&D, and design.
                                    www.egs.co.in
                                    www.egsindia.com
Checklist for DFQ

✔ Is the Drawing Correct?
✔ Is the Drawing Complete with Respect to Functional Tolerancing?
✔ Has Process Capability been incorporated while selecting
  Tolerances?
✔ Has Assembly Build Criteria been defined?
✔ Has Interference Analysis been performed?
✔ Have Critical Dimensions for Assembly Build been identified?
✔ Have tolerances been maximized for required Assembly Build?
✔ Have Tolerances been optimized for least cost?
✔ Is the PPM Estimate meeting our Business Profitability Objective?
✔ Is there a Dimensional Verification Plan?



                                                   www.egs.co.in
                                                   www.egsindia.com
Dimensional Management Techniques

• Develop G D & T / Plus-Minus Tolerancing
  Schematic using DimXpert inside SolidWorks
• Perform Assembly Build Analysis using
  SigmundWorks inside SolidWorks
• Update SolidWorks Drawing with Optimized
  Tolerances
• Establish CMM Inspection Program
  automatically from SolidWorks Drawing using
  PAS-CMM for SolidWorks


                                   www.egs.co.in
                                   www.egsindia.com
GD&T         Vs Plus/Minus Tolerancing

Plus/Minus Tolerancing     Geometric Tolerancing




                                       www.egs.co.in
                                       www.egsindia.com
GD&T Drawings using DimXpert




                               www.egs.co.in
                               www.egsindia.com
Answers to Quality Challenges

           CAD Part Geometry       Product Specification




             Tooling Geometry        Process Capability



           Assembly Sequence &
                                    Measurement Plan
                Index Plan




            Dataset Tolerances,        Cost Optimized
                                   Tolerance Cost Drivers
            Datum and GD & T             Tolerances



              PPM Estimation        Key Characteristics




           Inspection Dimensions       Performance

                                                            www.egs.co.in
                                                            www.egsindia.com
Dimensional Management Plan

• Assured Quality on
  adherence to DM Plan
• Eliminates Cost due to
  Poor Quality
• Ensures Quality in First
  Prototype !




                              www.egs.co.in
                              www.egsindia.com
Tolerance Analysis Vs Tolerance Synthesis




                                www.egs.co.in
                                www.egsindia.com
Setting Build Objectives




                           www.egs.co.in
                           www.egsindia.com
Setting Build Objectives




                           www.egs.co.in
                           www.egsindia.com
Defining Node Tree of
Dimensions & Tolerances




                          www.egs.co.in
                          www.egsindia.com
PPM Estimates




                www.egs.co.in
                www.egsindia.com
Identifying Contributors




                           www.egs.co.in
                           www.egsindia.com
Incorporating Process Capability




                                   www.egs.co.in
                                   www.egsindia.com
Updating SolidWorks Drawings




                               www.egs.co.in
                               www.egsindia.com
Establishing Dimensional Inspection
Process with PAS-CMM




• Automated CMM Programming from 3D CAD Designs
• Reduces CMM Programming time by 90%
• Eliminates ambiguity in drawing interpretation

                                      www.egs.co.in
                                      www.egsindia.com
Summary of Benefits

•   Correctness & Completeness of Drawings assured
•   Assembly Issues are eliminated
•   Maximized Tolerancing for Least Cost
•   Identification of Critical Dimensions affecting Assembly
    Build & Performance
•   Estimate Rejections a priori
•   Establish Dimensional Inspection FREE OF ERRORS
•   Eliminates customer rejection of parts/ assemblies
•   Ensures Consistent Quality
•   Reduces/ Eliminates Human errors in subjective
    interpretation of drawings that result in re-work, time
    delays and escalates product cost
                                                 www.egs.co.in
                                                 www.egsindia.com
Thank You




      Interested in Design for Quality?
          Contact: info@egs.co.in
   Web: www.egsindia.com www.egs.co.in
                               www.egs.co.in
                               www.egsindia.com

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Design for-quality

  • 1. Design for Quality: Achieving 0 Rejection – A Reality Natarajan R Director EGS India
  • 2. Agenda • Introduction to Design For Quality – DFQ • Checklist for DFQ • Dimensional Management Techniques • Predicting Assembly Build • Automating Inspection Process • Summary www.egs.co.in www.egsindia.com
  • 3. Introduction to DFQ • What Tolerance to allocate? • How will the tolerances affect function? • Will there be any assembly issues? • What will be the PPM estimates? • Is it really necessary to tighten tolerances? • Have I chosen the right tolerance? • Am I responsible for increasing the product Cost? www.egs.co.in www.egsindia.com
  • 4. Did You Know? Only about 60% of new products launched are actually a success and that for every seven new product ideas, only four make it to development — and then only one succeeds. Source: Winning at New Products: Accelerating the Process from Idea to Launch - Robert G. Cooper www.egs.co.in www.egsindia.com
  • 5. DFQ: Definition of Paradigm • Superior Functionality • Best Fit • Least Rejections • Highest Customer Satisfaction • Consistent Performance www.egs.co.in www.egsindia.com
  • 6. Quality Issues • Parts not aligning well for a perfect Fit • Vibration & Noise due to moving parts • Inconsistent Life & Performance under Controlled Testing • Unpredictable Field Failures www.egs.co.in www.egsindia.com
  • 7. Improper Fit www.egs.co.in www.egsindia.com
  • 8. Vibration - Effects www.egs.co.in www.egsindia.com
  • 9. Vibration & Noise www.egs.co.in www.egsindia.com
  • 10. Field Failures www.egs.co.in www.egsindia.com
  • 11. Six Sigma Approach www.egs.co.in www.egsindia.com
  • 12. Design for Six Sigma (DFSS) • Objective is to Understand the Root Cause and Eliminate Defects • Maximize Return on Investment • Incorporate Processes for Continuous Improvement • Enables Gap Analysis of entire Product Development System • Addresses Voice of Customer (VOC) www.egs.co.in www.egsindia.com
  • 13. 5 Steps in DFSS • Plan—enable the team to succeed with the project by mapping all vital steps • Identify—hear the voice of the customer to select the best product concept • Design—build a thorough knowledge base about the product and its processes • Optimize—achieve a balance of quality, cost, and time to market • Validate—demonstrate with data that the voice of the customer has been heard and that customer expectations have been satisfied www.egs.co.in www.egsindia.com
  • 14. DFSS – Another Perspective • Define—determine the project goals and the requirements of customers (external and internal) • Measure—assess customer needs and specifications • Analyze—examine process options to meet customer requirements • Design—develop the process to meet the customer requirements • Verify—check the design to ensure that it’s meeting customer requirements www.egs.co.in www.egsindia.com
  • 15. SS Vs DFSS • DMAIC is more focused on reacting, on detecting and resolving problems, while DFSS tends to be more proactive, a means of preventing problems. • DMAIC is for products or services that the organization offers currently; DFSS is for the design of new products or services and processes. • DMAIC is based on manufacturing or transactional processes and DFSS is focused on marketing, R&D, and design. www.egs.co.in www.egsindia.com
  • 16. Checklist for DFQ ✔ Is the Drawing Correct? ✔ Is the Drawing Complete with Respect to Functional Tolerancing? ✔ Has Process Capability been incorporated while selecting Tolerances? ✔ Has Assembly Build Criteria been defined? ✔ Has Interference Analysis been performed? ✔ Have Critical Dimensions for Assembly Build been identified? ✔ Have tolerances been maximized for required Assembly Build? ✔ Have Tolerances been optimized for least cost? ✔ Is the PPM Estimate meeting our Business Profitability Objective? ✔ Is there a Dimensional Verification Plan? www.egs.co.in www.egsindia.com
  • 17. Dimensional Management Techniques • Develop G D & T / Plus-Minus Tolerancing Schematic using DimXpert inside SolidWorks • Perform Assembly Build Analysis using SigmundWorks inside SolidWorks • Update SolidWorks Drawing with Optimized Tolerances • Establish CMM Inspection Program automatically from SolidWorks Drawing using PAS-CMM for SolidWorks www.egs.co.in www.egsindia.com
  • 18. GD&T Vs Plus/Minus Tolerancing Plus/Minus Tolerancing Geometric Tolerancing www.egs.co.in www.egsindia.com
  • 19. GD&T Drawings using DimXpert www.egs.co.in www.egsindia.com
  • 20. Answers to Quality Challenges CAD Part Geometry Product Specification Tooling Geometry Process Capability Assembly Sequence & Measurement Plan Index Plan Dataset Tolerances, Cost Optimized Tolerance Cost Drivers Datum and GD & T Tolerances PPM Estimation Key Characteristics Inspection Dimensions Performance www.egs.co.in www.egsindia.com
  • 21. Dimensional Management Plan • Assured Quality on adherence to DM Plan • Eliminates Cost due to Poor Quality • Ensures Quality in First Prototype ! www.egs.co.in www.egsindia.com
  • 22. Tolerance Analysis Vs Tolerance Synthesis www.egs.co.in www.egsindia.com
  • 23. Setting Build Objectives www.egs.co.in www.egsindia.com
  • 24. Setting Build Objectives www.egs.co.in www.egsindia.com
  • 25. Defining Node Tree of Dimensions & Tolerances www.egs.co.in www.egsindia.com
  • 26. PPM Estimates www.egs.co.in www.egsindia.com
  • 27. Identifying Contributors www.egs.co.in www.egsindia.com
  • 28. Incorporating Process Capability www.egs.co.in www.egsindia.com
  • 29. Updating SolidWorks Drawings www.egs.co.in www.egsindia.com
  • 30. Establishing Dimensional Inspection Process with PAS-CMM • Automated CMM Programming from 3D CAD Designs • Reduces CMM Programming time by 90% • Eliminates ambiguity in drawing interpretation www.egs.co.in www.egsindia.com
  • 31. Summary of Benefits • Correctness & Completeness of Drawings assured • Assembly Issues are eliminated • Maximized Tolerancing for Least Cost • Identification of Critical Dimensions affecting Assembly Build & Performance • Estimate Rejections a priori • Establish Dimensional Inspection FREE OF ERRORS • Eliminates customer rejection of parts/ assemblies • Ensures Consistent Quality • Reduces/ Eliminates Human errors in subjective interpretation of drawings that result in re-work, time delays and escalates product cost www.egs.co.in www.egsindia.com
  • 32. Thank You Interested in Design for Quality? Contact: info@egs.co.in Web: www.egsindia.com www.egs.co.in www.egs.co.in www.egsindia.com