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Design for-quality

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Design for Quality using Six Sigma approach, empowers Design engineers to know upfront the assembly build quality, correctness and completeness of drawings and their tolerances of features and provide …

Design for Quality using Six Sigma approach, empowers Design engineers to know upfront the assembly build quality, correctness and completeness of drawings and their tolerances of features and provide inspection using Automated Programming with PAS-CMM

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  • 1. Design for Quality:Achieving 0Rejection – AReality 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 areactually a success and that for every seven newproduct 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 TolerancingPlus/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 ofDimensions & 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 InspectionProcess 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