Quality Engineering Principles and Analysis ~ Six Sigma ...



MFG 599-3: Designing in Quality: From Customer Requirements through Product ValidationPat Hammett, PhD (phammett@umich.edu)On Campus Class Meeting Time: MW 12:00– 1:30 in 165 Chrysler CenterIOE Office: 1777 IOE (tue office hrs only)Office Hrs: TUE 4-5:30 PM (IOE)Main Office: 405 UMTRI Building*UMTRI Phone: 734-936-1121 (Voice Mail)*Note: Available by appointment at UMTRI Office (UMTRI Building: Huron Parkway/ Baxter) SessionTopicAssignment1Course Introduction – New Product Development and its Challenges, Embedded DFSS2Identify DFSS Project Opportunities IDDOV Methodology 3Define Customer Requirements: Voice of the Customer Requirements GatheringNO CLASS MLK Break4Survey Analysis Methods5Product and Process Functional Requirements: FAST Diagram (Block Diagram)Ex 1 Due6Requirements Flow Down and House of Quality I7Design Concept Generation: Innovation and Creative Thinking Techniques8TRIZ Overview9Design Concept Selection: Pugh Matrix, House of Quality IIEx 2 Due10Design Failure Mode and Effects Analysis (DFMEA)11Design Issue Countermeasures, DFX Analysis, Axiomatic Design Principles: In-class Exercise – Designing Toys12Student Presentations – In ClassCase I Due Feb 19No Class – SPRING BREAK13Design Optimization: Design Transfer Functions and P-Diagrams14Midterm Exam (in class)15Conventional Design of Experiments16Taguchi Robustness Concepts17Taguchi Design of Experiment18Design Optimization Using Response Surface Methodology19Design Optimization Using Transfer Functions and SimulationEx 3 Due20Multi-Response Optimization and Desirability21Reliability Testing22System Reliability Allocation23Tolerance Analysis: Statistical Tolerance Models and SimulationEx 4 Due24Tolerance Development and Allocation 25Validation: Product Design Verification (Prototypes, Simulations) / Updating ScorecardEx 5 Due26Manufacturing Process Validation 27Course SummaryCase 2 DueFINAL Exam – TBD Final ExamCourse Web Page:ctools.umich.eduLecture Notes:All lecture notes, homework sets, solutions, and tutorials are available through the course web page. Course Text Book:The course lecture notes have been developed from a variety of sources. TEXTBOOK REFERENCE:Design for Six Sigma: A Roadmap for Product Developmentby Kai Yang, Basem S. EI-Haik -- IBSN: 0-071-412085Others Reference Books Used in the Course:Taguchi’s Quality Engineering Handbook G. Taguchi, S. Chowdhury, and Y. Wu, Wiley-Interscience, ISBN: 0471413348Axiomatic Quality: Integrating Axiomatic Design with Six Sigma, Reliability, and Quality Engineering B. El-Haik, Wiley-Interscience, IBSN: 047168273XEngineering of Creativity: Introduction to TRIZ Methodology of Inventive Problem Solving S. Savransky, CRC Press, ISBN: 0849322553Response Surface Methodology: Process and Product Optimization Using Designed Experiments R. Myers and D. Montgomery; Wiley-Interscience, IBSN: 0471581003Software: ? Minitab 14 Software or equivalent and QETools Templates ProvidedUseful Web Sites:Product Development: bok.htmlSix Sigma: Instructor:Statistics Material: DFSS Books:- Design for Six Sigma in Technology and Product Development by C. Creveling, J. Slutsky, D. Antis- Design for Six Sigma: Launching New Products and Services without Failure by Geoff Tennant Course GradingAssignmentPointsMultiple Choice Exercises (5)50Case Study Reports (2)90Class Participation/Discussion Board40Exam I100Final Exam 120Total400Homework: (all homework must be submitted electronically – see instructions on web page).Case Study Assignments: Assignments must be emailed using a single report file. Acceptable file submittal formats: (Adobe PDF or MS Word) – For additional format issues on page lengths and headings: See “Case Study Report Requirements”. Case #Topic Points#1 IDD – Design Concept Selection40#2 Design Robustness and Optimization50Case Study and Exercise Submittal Policies:Case Study Assignments should be completed in teams of ~3. All assignments submitted electronically must be posted by 11:59 PM of the assigned due date.For on-line multiple choice exercises, no late homework submittals will be accepted.For case study reports, students may turn in one case study four calendar days after it is due. If you turn in an assignment after the late date or have more than one late assignment, the maximum score possible for that assignment will be 20 points. Case studies are considered a critical component of this course and students are expected to complete all case study reports. Failure to complete a case study will result in an additional loss of 20 points (beyond a 0 for the assignment) AND a lowering of your final grade. Discussion Board/Participation Score (all student discussion posts must be completed by last day of class):Throughout the course, I will post various discussion questions within ctools – See ‘Discussion Tab’. For off campus students, I will expect you to respond to at least 4 of these (responses should be 1-2 paragraphs in length). Students may create 1 blog/discussion thread of their own at part of their 4 discussion posts (Blog on a Topic of personal interest). I will evaluate your participation score based on the quality of your discussion postings (Note: you are also welcome to add to in-class discussions).For on campus students, I will evaluate your participation score based on a combination of attendance, participation in classroom discussions, and response to at least 2 instructor discussion posts. Students may create 1 blog/discussion thread of their own at part of their 4 posts (Blog on a Topic of personal interest).Course Description:As organizations improve their operational quality, they recognize the need to apply more systematic analytical techniques to design quality into their products and services. This course provides methods and analysis tools for preventing quality and warranty concerns. This course focuses on the Design for Six Sigma Quality methodology: IDDOV. Using the IDDOV framework, this course examines tools and methods for identifying customer requirements, evaluating design concepts, and optimizing processes to meet quality objectives. The course integrates several tools from Voice of the Customer Analysis, Transfer Functions, Failure Mode Effects Analysis, TRIZ, DFX Analysis, Experimental Design, Taguchi Methods, Response Surface Methodology, Design for Reliability, and Tolerance Simulation and Analysis.Course Objectives and Outcomes:course objectivesLinks shown in brackets are to departmental educational objectives: 1 Know how to apply basic statistical procedures to solve engineering problems.2 Build a base of skills in drawing conclusions from data using modern statistical software 3 Learn how to gather design requirements and build quality into a product or service. 4 Integrate statistical analysis tools with quality problem solving methodologies.COURSE OUTCOMESLinks shown in brackets are to course objectives:1 Appreciate the challenges with gathering customer requirements and developing new products and services.2. Learn innovation and design analysis techniques to create products that better meet customer requirements.3. Know graphical and numerical techniques for summarizing and presenting data.4. Know methods for drawing valid conclusions (inference) for different situations such as tests of hypothesis. ................
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