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Lean Product Development - Asqmilwaukee

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Lean Product Development - Asqmilwaukee Powered By Docstoc
					              Quality-One
                 Lee D Dawson
                 248 280 4800



Lean Product Development
 • How to Use Risk Determination to Increase
   Velocity of Product Development

                                               1
• Product Development is the lifeblood of an organization.
  • Successful Future product and service offerings keep the
    customers coming back.
• We strive relentlessly, for products and services which
  delight our customers assuring loyalty and future success.
• With so much riding on product development and the
  ever increasing complexity of our products and services,
  how do we decrease the potential for failure and
  simultaneously, increase our velocity to market?




Lean Product Development                                       2
• Increased Velocity to market with a product or
  service, “that exceeds the customer’s expectations” some
  say is impossible.
  • More time “not less” is required to assure reliability.
• The purpose of this discussion is to challenge the notion
  that speed and effectiveness are not compatible.
  • Taking less time to get a product in the marketplace is
    indeed practical and possible.




Lean Product Development                                      3
• Risk can play a critical role as a measure of progress and an
  indicator of future reliability and quality.
• The measurement of risk as a substitute for actual failure has
  led teams to faster product/service introduction (10% + faster)
  with far fewer concerns than if driven by physical test failures
  of prototypes (60% less issues).
• Managing Risk in product development, as a primary indicator,
  keeps the teams focused and provides discipline in
  • Design Reviews,
  • Test Planning,
  • Effective and least expensive Quality Controls at launch




Lean Product Development
                       4
• What is Lean Product Development?
  • Lean PD is a term which describes the removal of wasteful
    steps that may exist within the PD process.
• Often, success of Lean PD has been translated into two
  measures
  • Speed to market
  • Improved Reliability



Premise of Lean Product
Development                                                     5
• Reliability and going fast are believed to be mutually
  exclusive and in reverse correlation to one another.
  • And many times they can be.
• This is due to specific type of waste that exists in PD




Premise for Lean Product
Development                                                 6
 • Waste comes in several basic forms
   • Muda - Non productive or non value added
   • Mura - Unevenness
   • Muri - Over burdened




What waste exists in PD?
                                                7
• Muri
  • Is the specific waste that exists in Product Development
• Over-burdening (Muri) PD comes from two of the seven wastes
  • Over processing
     • Trying to do too much in a limited (typically reduced) time to
       market opportunity.
        • In PD, a relationship exists between content change and time
          to market.
  • Waiting
     • Time is wasted between the time a failure is created from the
       point in time it is found.
        • Too much emphasis on evidence before taking counter
          measures




What waste exists in PD?                                             8
Trying to do Too Much.
      Over processing

                         9
• Product Development is a Failure Factory
• Each click of a mouse in a CAD system, material selection, or
  process method selected brings with it the potential for failure.
• Failure is an act of the Design Engineer both product and
  process
• Failure must be avoided or controlled before the product can
  come in contact with the customer.
• But how many failures are there to find and prevent/control?
  • This is the great unknown of Product Development




The Failure Factory                                              10
                                 2 Failure Mode Discovery




                                                                                         Number of counter-measures
                                 (3 Counter Measure adopted)
Number of failures found




                           1 Failure Mode Creation




                                                                    Cost of developing
                                                                    Counter-measure

                 0
                           T1               T2       T3        T4           T5




                                                                                                                      11
• The integral or area under the curve is determined by the
  quantity of change that is being managed in the PD process
  • Small amount of change lowers the height of the curve
  • Large amount of change creates a higher curve.
• The volume of the curve is also “unfortunately” unknown
  • We do not know the number of failures that exist when we are
    creating value in new products or services
• To not acknowledge the amount of failure can often lead to:
  • Issues at launch
  • Reduced life of the product or service.




Trying to Do Too Much
                                 2 Failure Mode Discovery




                                                                                         Number of counter-measures
                                 (3 Counter Measure adopted)
Number of failures found




                           1 Failure Mode Creation


                                          Program Risk


                                                                    Cost of developing
                                                                    Counter-measure

                 0
                           T1                T2          T3    T4           T5




                                                                                                                      13
• Program New or Changed Content is managed through
  the use of a Risk Model
• Risk Models separate the new content into several
  categories.
     • Red- Primary Function and Impact on Safety
     • Orange- Performance affecting Customer acceptance
     • Yellow- Annoyance managed when highly likely
     • Green- Low Risk which is optimized in PD



Managing Program Risk                                 14
• An established Standard Criteria for Program Risk Level
  is integral to Lean PD.
• A 70/30 Ratio is the greatest amount of risk that can be
  managed for velocity to market.
   • 70 % Validated
   • 30% New/Changed/Poor History/Environment
      • Less is better but may not be avoidable.




Managing Program Risk                                    15
• Red Risk greater than or equal to 10% or total new or
  modified changes (including past failure) requires
  resource assessment.
  •   Personnel “Person Hours”
  •   Time to task “estimated”
  •   CAE or simulation capability and availability
  •   Distance in Collaboration “Co-Located”
  •   Difficulty to achieve “ Design Risk Ranking”
  •   Time Estimate is established based on assessment.
• Orange Risk greater than 20 % alone or 30% accumulated
  with Red Risk requires resource assessment.
• Yellow Risk is managed as exceptions as experienced.

 Program Risk Guidelines                                  16
      Primary New Function / Safety              30% Max
                                                 Requirement/ or
         Performance/Satisfaction                specifications
                                                 Change

           Business/Control Risk


                 Minor Risk
                                70 % validated
                                Standard Work




Risk Model Illustration
                                   QFD (Quality Function Deployment)
 Safety /      Design
Regulatory     Changes             is a great risk tool
                                                                          Define Level of Program Risk
                     Design Risk                                          •Red Risk
Technology           QFD Matrix     Supplied Product Risk                   •Technical Risk Assessment
/ Materials                             Assessment
                                                                            •Due Diligence
                                                  5




                                    Design Risk
                                                  4                         •Design Reviews
                                                  3
                                                  2
                                                                          •Orange Risk
Manuf.                                            1
                                                      1   2   3   4   5     •Technical Risk Assessment
Technology                                            Supplier Risk
                                                                            •Design Reviews
                     Manuf Risk.
                                                                          •Yellow Risk
                     QFD Matrix
  History                                                                   •Kaizen projects as needed
                                                                          •Green Risk
                                                                            •Manage as exception only
               Process
              Capability
• Defining total amount of Risk permitted in a program
  allows for detailed resource planning based on time and
  available personnel
• Keeping the risk at 30% accumulated:
  • New Content
  • Changes/Modification to current product and or process
  • Past History of Failure
• Can reduce by 10% the time to Market




Expected Results                                             19
Excess Time for Counter
      Measures.
        Waiting

                      20
• Failure modes discovered late in PD
  • Result in late changes due to the inescapable need for counter-
    measures when failure is found
  • “Every Failure Will Be Found”.
• Based on when counter-measures are determined, there
  may be insufficient time to verify and validate.
• If some counter-measures do not work, some failure
  modes will escape into the field.
 • This leads to customer dissatisfaction and warranty



Excess Time for Counter
Measures                                                              21
• Finding Failure early translates to the measurement of
  risk and subsequent mitigation.
• Looking for Risk in PD involves using:
   • Computer Aided Engineering (CAE) and Simulation
     Technology
   • Reliability by Design/Quality Planning Tools
    • Qualitative
    • Quantitative
  • Formal Technical Design Review (DRBFM)
  • Systems Engineering Test Strategies (V Model)

Excess Time for Counter
Measures                                                   22
                                 2 Failure Mode Discovery




                                                                                         Number of counter-measures
                                 (3 Counter Measure adopted)
Number of failures found




                           1 Failure Mode Creation




                                                                    Cost of developing
                                                                    Counter-measure

                 0
                           T1               T2       T3        T4           T5




                                                                                                                      23
                                                                                              Number of counter-measures
                                                     2 Failure Mode Discovery
                                                     (3 Counter Measure adopted)
Number of failures found




                           1 Failure Mode Creation       Risk Discovery and mitigation
                                                         drives the curve to the left
                                                         achieving lower cost and speed




                                   time
                                                                         Cost of developing
                                   minimized                             Counter-measure
                 0
                           T1                  T2         T3           T4             T5




                                                                                                                           24
• Risk is the defined as the likelihood of an
  objectionable event.
  • Hazard/Failure or Fault
     • Severity
  • Likelihood or Failure
     • Occurrence/ Failure Rate/ Likelihood
  • How well we measure risk, is determined by:
     • The legacy information available or what is known.
     • The tools and techniques utilized to discover risk.
     • Level of unknown New/Modified etc...




What is Risk?
• In Lean Product Development (PD), risk is the substitute
  for failure.
  • Risk is treated exactly the same as failure.
  • When risk is great enough, mitigation is required.
• When risk is measured objectively,
  • Actions (counter measures) can be taken to mitigate
     the risk, prior to introduction of the product.
• A risk based Design Review process is an integral part of
  a successful Lean Product Development process.




Lean PD and Risk
                                                                            Dow NPI
                             T1        T2                T3        T4
counter-measures
 Latitude to take




                                                                             # failure modes
                                                                                    found
                    Hard to find, easy to fix   Easy to find, hard to fix

                           Time

                          Qualitative QRR       Quantitative MRR


   Address Failure Modes Early
• Each unique PD project brings with it new and inherent
  risk.
• Reliability and Quality Tools are selected based on the
  potential risk that is potentially present:
   • Intentional
   • Incidental
• Intentional risk exists when change is introduced within
  the design
   • Materials
   • Geometry
   • Interfaces


Types of Risk
• Risk Models for each selected reliability/quality planning
  tool are utilized to drive actions as far forward in PD as
  possible.
   • Lower cost counter measures
   • Easier to implement counter measures
   • Avoid failure discovery at testing or in the hands of the
     customer
• Design Reviews (DRBFM concept) integrate risk actions.
• Reliability growth is measured with risk until test results
  demonstrate quantitative reliability growth




Risk Model
• Incidental risk exists when new environments and
  change occurs outside of the design.
  • Environments
  • Duty cycle/customer usage profile
  • Degradation conditions
• Tools are selected based on the potential risk that is
  likely to be present.
• A Product Development Reliability/Quality Plan is
  developed by a core team for the PD project.



 Product Quality Plan
                                                                        History / FMA (Failure Mode




                                                                                                                                                                                                          Engineering Design…RCL
                                                                                                      Design Standard/Spec.
                                                   Impact on Customer




                                                                                                                                                                              Simulaion/Modeling




                                                                                                                                                                                                              RED (Robustness




                                                                                                                                                                                                                                                                       QRR / MRR Index
                                                                                                                                                             Pdiagram Noise
                                                                                                                                            Boundary Diag.




                                                                                                                                                                                                                                                        MRR (DVP&R)




                                                                                                                                                                                                                                                                                         Structure sub.


                                                                                                                                                                                                                                                                                                          High Voltage


                                                                                                                                                                                                                                                                                                                         Low Voltage
                                                                                                                              Calculation




                                                                                                                                                                                                                                                                                                                                                 Cell Modual
                                                                                  Analysis)




                                                                                                                                                                                                                                                                                                                                       Thermal
                                                                                                                                                                                                   FMEA




                                                                                                                                                                                                                                          Audit




                                                                                                                                                                                                                                                  QRR
                                                                                                                                                                                                                                   Test
            System Requirements
 (For complete information see individual SDS)




Static clearance between body and battery
incompressible (excluding foam seals, dampeners,
etc) at locations > 20 mm from attachments( mm):
>7



                                                    5                                                                          3             3                                 9                   1                                      3       80    15            5.33                9                6              6            6                       6
Dynamic decking clearance between decking tool -
battery assembly, and body door opening (mm): >
25 + program specific information




                                                    5                                                                                        3                                 3                                                   9              30    45            0.67                9                6              6            6                       6
Battery system Mass including cells and brackets
(kg).
 Mass < 300 (Stretch Target <270)




                                                    5                                                                          3                                               9                   1                               9              65    45            1.44                3                6              6            6                       9




       Product Quality Plan
• Reliability/Quality plan including qualitative and quantitative
  techniques are aligned to the Lean PD process.
  • Map each requirement against each subsystem and assure written
    specifications are present.
     • Derived from transfer function.
       • Reliability matrix method
  • Align qualitative tools (QRR) to requirements
     • Tool qualification (Quality of Event)
     • Accumulate probabilities (probable PPM)
  • Map quantitative tests (MRR) against requirements
     • DVP&R
     • Test Protocols
     • System Engineering Cascade



  Product Quality Plan
                                                                                                         1.0 Plan & Define the Project                                                                                                       HVPD

                                                                                                          1.0 Planning
                                                                                                                                                  1.1 VOC                                                                     Product Development
                                                                                                                         -New Requirements
                                                                                                                                                                                       As Required:
                                                                                                                         -Wants/Needs/Desires
                                                                                                                                                                                       1.2 Business/Market Plan
                                                                                                                                                                                       1.3 Product/Process Bench Data
                                                                                                                                                Regulations         1.1 QFD
                                                                                                                                                  Input             Requirements
                                                                                                                                                                    Specifications
                                                                                                                                                                    1.7 Design Goals


                                                                                                                                                                     Develop                 1.11 Preliminary
                                                                                                                                                 1.1 FMA                                                                 1.10 Preliminary
                                                                                                                                                                     Concept                 List of Special
                                                                                                                                                Quality History                                                            Process Flow
                                                                                                                                                                     Designs                 Characteristics




                                                                                                                                                                                                                                                                        TIME
                                                                                                                                                                                                                                                                  T1
                                   3.0 Process Design & Development

                                                                      2.0 Product Design & Development




                                                                                                                             2.0 Design &                            2.6 Product              2.2 DFA/ M                  3.3 Process
                                                                                                                                                                                                                                             3.0 Process Design
                                                                                                                                                       Robust
                                                                                                                               Develop                               2.7 Design                     DF(x)                    Flow                & Develop

                                                                                                                                                                                                2.11 Special                  3.5
                                                                                                                                                                     2.1 DFMEA
                                                                                                                                                                     Path 1 & 2                 Characteristics          Characteristics
                                                                                                                                                                                                                            Matrix



                                                                                                                                                                                           •Special Characteristics
                                                                                                                                                                        2.1 DFMEA          •Error/Mistake Proof
                                                                                                                                     DVP&R                               Path 3            Collaboration                  3.6 PFMEA
                                                                                                                                                                  Test Development        -•Improved Statistical                                                  T2
                                                                                                                                                                                           Capability



                                                                                                                                                                    2.6 Engineering                                     3.7 Pre Launch
                                                                                                                                                                    Drawing. Design                                     Control Plans
4.0 Product & Process Validation




                                                                                                                                                                    Tooling Drawing                                                                               T3

                                                                                                                                                                                                                        4.1 Production           4.7 Production
                                                                                                                                                                                                                           Trial Run              Control Plan

                                                                                                           4.0 Product & Process Validation
                                                                                                                                                                                                                         4.3 Preliminary            Process
                                                                                                                                                                                                                        Process/Capability        Instructions
                                                                                                                                                                                                                             Studies
                                                                                                                                                                                                                                                                   T4
                                      Product
         Requirements               Specifications
           Targets

                             Phase                    Systems / Sub-Systems /
                             Progression                Components BOM


                                           Subsystem/
                                             parts                                  Interface analysis
                                                                                   Geometry Boundary
                                                                                    Diagram/Interface
                                                                                          Matrix
  Design
Requirements

                                                                                 System Tolerance Stacks
                                                                                      Proposed RSS



         Design Product
         Specifications
        NEM/NES//NDS                                                            Component Tolerance
       New Program targets
          Past history                                                              Stack-up

                                                                                System DFMEA
                                                                                   Sub-System DFMEA

                                                     Fault Tree                      Component DFMEA
               Cascade                               Analysis

                                                                                                           34
                                                      Process Operations and surrogate
      System DFMEA                                          variation per CPPD
       Sub-System DFMEA
         Component DFMEA

           Fault Tree Analysis

                                                                                         High Priority Process
                                                                                             Operations


Select Datums and Geometry for                                                                        Tolerances refined
  Special /Key Features Spec
         Char Initiated
         (Risk Based)



                                                                                                      Refined Tolerance stack
                                                      Spec Char                                        and GD&T Locked
                                                      Collaboration


Cascade of Special                   SC’ and KF                Release
                                  From all DFMEA’
    and Key                           and FTA                  design
                                                                                                                            Special
                                 And SC and KF from
 Characteristics                       Stock                                                 Process FMEA                   Controls


                                                                                                                 Control Plan


                                                                                                                           35
• Each risk which is discovered requires mitigation.
• Risks are carried over to the design review for specific
  details and review of the results.
• Decisions are made as to the credibility of the risk and the
  successfulness of the mitigating counter measure.
• Risks are tracked against a target Glideslope chart.
• Risk levels at each stage of Lean PD are assessed at
  Project Gateways (T1, T2, T3 etc…)
• Progress against Targets allows for quick action to get
  back on the Glideslope


Design Review Based on
Failure                                                    36
      DR Inputs
   -Reliability Tools
       -DFMEA’s
        -PFMEA’s                Design Review / Risk Mitigation
      -Test Failures
    -Process Failures
                                                                                        Pareto
                                                                               ROY
     Action Matrix                                                                     By Risk
                                                                               Chart




                                                                                                 Design Review
                           •Time / Date
    Sort Matrix for
       Design              •Name / Responsibility
       Review              •Risk Level




                                                                                                                 Glide Path
        Design
        Review


                           Yes                                                          Pareto
         Risk                                                                  ROY
       Mitigated?
                                                    Update                             By Risk
                                                                               Chart
               No
       Reassign                   •New Action
Responsible / New Action          •New Date
                                                                                        Pareto
                                                                               ROY
                                                                                       By Risk
    Update Action                                                              Chart
       Matrix
                                                           (248) 280 - 4800
                           Rev. Date 4/12/10             www.quality-one.com
• Reliability growth is based on qualitative methods (Risk
  Measurement)
  • Design Review criteria for each tool/method outcome.
    • Red= Primary/New Function/Critical/Safety
    • Orange= Significant/Performance
    • Yellow= Controls Strategy/Kaizen/As Experienced
• Tools aligned to (T gateways), accumulate/stack Reds,
  Oranges, and Yellows
  • Risks that have been successfully mitigated permit
    program to move into final product certification and
    delivery



Risk Tracking
                                                DFMEA/PFMEA CUMULATIVE
   70                                                  ROY CHART


   60
                                                               59
                                                               59



                                                                        51
                                                                        51
   50
                                                               47
                                                               47


   40
                                                                                                                                                     RISK
COUN
COUNT                                                                   37
                                                                        37
                                           35
                                           35        35
                                                     35
                                                                                                                                                         Red
   30                                                                                                                                                    Orange
                                                                                                                                                         Yellow
             24
             24        24
                       24        24
                                 24
                                                               23
                                                               23
   20
                                                                        19
                                                                        19
                                           18
                                           18        18
                                                     18
             16
             16        16
                       16        16
                                 16
                                                                        GLIDE PATH
   10
                                           8
                                           8         8
                                                     8                                                                                               Red Risk
             6
             6         6
                       6         6
                                 6
                                                                                                                                                      Target

    0
        T1 .25    T1 .50    T1 .75    T2 .25    T2 .50    T2 .75    T2.80    T3 .25   T3 .50   T3 .75   T4 .25   T4 .50   T4 .75   T5 .25   T5 .50



                                                                   PD TIMELINE
• A Product Quality Plan deployed against the potential risk
  separates the Vital Few from the Trivial Many possible
  things that can go wrong
   • Keeps the Team Focused
• The methods/tools and techniques selected in the PD
  specific Product Quality Plan, push actions based on Risk
  not actual failure at prototype or in the testing stages.
• Fewer changes occur post design release (Up to 60% less
  when compared to previous programs of similar size)
• Tools Linkage provides next inputs from derived outputs
   • Not a checklist to show we did it, instead measuring
     actual actions against risk

Results                                                   41
Product Quality Plan
     Risk Mitigation Examples

                                42
• Failure Modes are initially based on requirements and
  specifications
  •   Full
  •   Partial (Too Little/Too Much)
  •   Intermittent
  •   Unintentional
• Causes are:
  • Part/component specific
      • Geometry
      • Physical properties
      • Chemistry


FMEA Failure Modes/Cause
Mechanisms
• Causes are:
  • Interface and Interaction
    •   Physical
    •   Energy transfer
    •   Material transfer
    •   Data transfer
  • Noise Factors
    • Stresses, customer/installer misuse, environments, degradation,
      sensitivity to variation

  • Follow the    “ION” technique
FMEA Failure Modes/Cause
Mechanisms
                                                                                                             Potential
                                                                                                 Failure Mode and Effects Analysis
 ___ System                                                                                                       (Design FMEA)
 ___ Subsystems                                                                                                                                                                 FMEA Number :
        Component :                                           Design Responsibility :                                                                                              Prepared by :
Model Year / Vehicle (s) :                                                Key Date :                                                                                         FMEA Date (Orig.) :                           (Rev.) :
             Core Team :




                                                                                                                                  Occurrence
                                                                                                                   Current                      Current                                            Responsibility          Action Results




                                                                          Severity
                                                                                             Potential Causes /




                                                                                                                                                           Detect
                                                                                                                                                                    R.P.N.
                                                                                     Class
                             Potential Failure   Potential Effects of                                               Design                      Design                       Recommended             & Target




                                                                                                                                                                                                                                                         Detection
                                                                                                                                                                                                                                      Severity
   Item / Function                                                                            Mechanisms of




                                                                                                                                                                                                                                                 Occur



                                                                                                                                                                                                                                                                     R.P.N.
                                  Mode                Failure                                                      Controls                    Controls                         Actions             Completion
                                                                                                  Failure                                                                                                         Actions Taken
                                                                                                                  Prevention                   Detection                                               Date




                         • Causes should be limited to design BOM, Interfaces and Noises (ION)
                         • Causes at component level analysis should be identified as part or system
                           characteristic (a feature that can be controlled at process)
                         • There is usually more than one cause of failure for each failure mode
                         • Causes must be identified for a failure mode, not an individual effect
                                 • Insulation material too thick
                                 • Inside cup sized incorrectly
                                 • Insufficient insulation



                                                                                                                                                                                                                                      45
• Inside
• Outside
• Noise

Remember the ION Principle
when developing DFMEA   46
• Causes from the Boundary Diagram
  • Components inside the boundary
    • Design Mistakes
  • Interfaces with other Systems
• Causes from P (Parameter)-Diagram (Design FMEA)
  • Noise factors
• Causes from past history (Failure Mode Avoidance FMA)
  • Warranty
  • Rejects
  • Internal COQ (Cost of Quality)
• New Causes not yet considered

Origin of causes in
Design FMEA                                           47
       Milwaukee Specific Example of a Boundary Diagram
                                 Handle Bars              Wiring Harness

                              Clearance       Vibration



                                Skin
Electrical
Console                         Valve
              Clearance
Seat                            Filler Neck
               Vibration
                                Filler Cap

Frame
                                Fuel Gage
               Vibration

                                Baffle / Filter
Fuel Line                       Bracket
             Filtered Fluid

                                Decal




                                   Interface
                                   -Physical
                                   -Energy Transfer
                                   -Mat’l Transfer
                                   -Data Transfer
                                    DFMEA Boundary
• Brainstorm all causes of failure mode at one time.
• Similar to a Fishbone / Cause-and-Effect diagram.
• Enter onto the form as brainstormed.




                              Failure Mode

                               ION for Design FMEA
                               6M for Process FMEA


Fishbone Ishakawa
Diagram                                                49
• Follow the ION principle
  • Inside (the boundary)
     • Components and details about the design
  • Outside (the boundary)
  • Interfaces of the 4 types
     •   Physical
     •   Energy
     •   Material exchange
     •   Data transfer
  • Noise
     • Environments
     • User and duty cycles
     • Degradation and sensitivity to variation
  • NEW Causes not covered by ION


DFMEA Cause Best
Practice is ION                                   50
                                                                                                                            When To Mitigate Risk


                          10
                                                                              Error Proof Zone
                           9
                                                                                                                        Zone One
                                                                                         Risk Mitigation Action
                           8                                                                    Required
                                                                              Statistical Capability/
                           7                                                  Low Cost Error Proofing
                                                                                                                        Zone Two
                           6
               Severity




                           5


                           4
                                                                                 Control Strategy

                           3    Risk Mitigation Action Not Required                          Risk Mitigation

                                                                                        Action Required if
                                 Look for opportunities to reduce costly
                           2     controls                                                          RPN >100           Zone Three

                           1
                                (FMEA team should consider if Risk Mitigation
                                                        Action should still be taken)
                                                                                                                      Zone Four

                                   1             2             3             4           5             6          7     8       9         10


                                                                                              Occurrence
  (248) 280 - 4800
www.quality-one.com
                               Rev. Date 4/12/10
• Risk Determined during DFMEA drives three additional activities in PD
  • DVP&R (Design Verification Plan and Reporting) test modification
  • Design Actions to reduce risk
  • Special Characteristics Development for CPPD (Collaborative
    Product Process Design) and Process FMEA
• The use of these linked tools allows for more detailed risk assessment
  and therefore closing in on potential Root Causes of potential failure
• And the process story board continues until
  • All Red Risk
  • Most Orange Risks
• Mitigated to a level of comfort for the team/program
  • Yellow risk as determined to be as necessary




  Cascade of Risk to Root Cause
Standard Work
Validated Processes, Constructions, Materials

                                                53
• As we learn and validate the processes and approaches
  we use, standardizing the Legacy has added benefits for
  PD Velocity
• Increased Product Development speed comes from
  avoiding developing a successful something over again.
• An Example where time is spent, but not always with
  great benefit is FMEA



Development of Standard
Work                                                    54
• A Lean Approach to FMEA provides the team with a set
  of known Failure Modes, Causes, and Verification
  methods to pick from.
  • Never do the same FMEA twice
  • Never do the Same Ishakawa Diagram twice
• Once you have a validated process, construction, or
  material stay with it until market pressure requires change
  • Change brings risk of Failure
• Use of Legacy increases speed
  • FMEA development time reduced by 70%.


Development of Standard
Work                                                       55
  Quality-One Legacy Matrix
           Core Competencies




Assembly                Fabrication




Painting                Welding
Q-1 Legacy Matrix
     Assembly

                    Technology
                    Blocks:
                    •Obtain
                    •Recognize
                    •Handle – Transport
                    •Prepare
                    •Position
                    •Attach
                    •Torque
                    •Connect
                    •Press
                    •Remove
                    •Route & Connect
                    •Fill – Fluids
                    •Validate
Q-1 Legacy Matrix
    Fabrication


                    Technology
                    Blocks:
                    •Obtain
                    •Recognize
                    •Handle – Transport
                    •Prepare
                    •Position
                    •Form
                    •Press
                    •Remove
Q-1 Legacy Matrix
      Paint


                    Technology
                    Blocks:
                    •Obtain
                    •Recognize
                    •Handle – Transport
                    •Prepare
                    •Position
                    •Paint
                    •Remove
                    •Fill – Fluids
                    •Inspect
Q-1 Legacy Matrix
     Welding


                    Technology
                    Blocks:
                    •Obtain
                    •Recognize
                    •Handle
                    Transport
                    •Prepare
                    •Position
                    •Weld
                    •Remove
                Q-1 Legacy Matrix
                Failure Modes / Causes


                                         Causes


Failure Modes
                Q-1 Legacy Matrix
         Failure Modes / Type 2 Controls

                                     Type 2 Controls


Failure Modes
                  Q-1 Legacy Matrix
                  Type 1 Controls / Causes


                                             Causes



Type 1 Controls
• Recognizing the waste (Muri) in the Product Development
  Process can drive a plan to make the PD process Lean
• Risks should be measured at Program Level and at the Technical
  Level
• Program Risk Level Activity
  • Limiting New Content/Modifications and Past Failures to 30% or less
    improves Velocity performance of PD
    • Speed can increase 10% with 30% new content and faster for less Change
• Technical Risk Level Activity
  • Creating a Reliability Plan to discover Failure Modes early in PD
    measures Risks, permits team to mitigate risk instead of wait for costly
    failure.
    • Reliability and Quality Tools, when linked do not slow PD, rather they increase
      the velocity to Market



 Summary
• Proper use of Legacy Capture and Lessons Learned drives the
  development of Standard Work
• Validated Standard Work is the Anti-Risk assessment:
  • Re-Using Validated Processes, Constructions, and Materials reduces
    risk
    •   Less FMEA
    •   Less Testing
    •   Less Validation
    •   Proven Capability
  • PD Velocity is increased using Legacy and Standard Work by
    applying what is already known
• Never Re-Learn the same information


   Summary
• Every program is plagued with the thought of how
  much performance improvement of the product or
  process is necessary before launch.
  • With everything there must be balance:
    • Remember the rule:
    • “The Enemy of the Good is the Better”
• It is generally true that a good product that makes it to
  market quickly is better than a Better product taking
  significantly more time to develop and launch.


   Summary

				
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posted:1/16/2013
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