Design for Quality and Product Excellence 2
• To investigate manufacturing specifications, consisting of nominal dimensions and
tolerances. Nominal refers to the ideal dimension or the target value that manufacturing
seeks to meet; tolerance is the permissible variation, recognizing the difficulty of
meeting a target consistently.
• Tolerance design involves determining the permissible variation in a dimension. A
scientific approach to tolerance design uses the Taguchi loss function. Taguchi assumes
that losses can be approximated by a quadratic function so that larger deviations from
target correspond to increasingly larger losses. For the case in which a specific target
value, T, is determined to produce the optimum performance, and in which quality
deteriorates as the actual value moves away from the target on either side (called
“nominal is best”), the loss function is represented by L(x) = k(x – T)2.
• To study the dimensions of reliability—the ability of a product to perform as expected
over time. Formally, reliability is defined as the probability that a product, piece of
equipment, or system performs its intended function for a stated period of time under
specified operating conditions. In practice, the number of failures per unit time
determines reliability during the duration under consideration (called the failure rate),
look at functional failure at the start of product life (The early failure period is
sometimes called the infant mortality period), reliability failure after some period of
use.
• To understand why reliability is often modeled using an exponential probability
distribution and use the reliability function, specifying the probability of survival, which
is: R(T) = 1 – e–T.
• To explore systems composed of individual components with known reliabilities,
configured in series, in parallel, or in some mixed combination, and how it ties into
various aspects of design, including optimization, tolerance design, and design
verification.
• To learn that design optimization includes setting proper tolerances to ensure maximum
product performance and making designs robust; a scientific approach to tolerance
design uses the Taguchi loss function. Techniques for design verification include
formal reliability evaluation, using techniques such as accelerated life testing and burn-
in.
• To examine the characteristics of Design Failure Mode And Effects Analysis
(DFMEA) — a methodology to identify all the ways in which a failure can occur, to
estimate the effect and seriousness of the failure, and to recommend corrective design
actions.
• Fault Tree Analysis (FTA), sometimes called cause and effect tree analysis, is a
method to describe combinations of conditions or events that can lead to a failure. In
effect, it is a way to drill down and identify causes associated with failures and is a good
complement to DFMEA.
• To investigate good product design, which anticipates issues related to cost,
manufacturability, and quality. Improvements in cost and quality often result from
simplifying designs, and employing techniques such as design for manufacturability
(DFM) – the process of designing a product for efficient production at the highest level
of quality.