INTRODUCTION FOR DESIGN FOR QUALITY AND RELIABILITY

Design for quality (DFQ) & Design for Reliability (DFR) not only ensures that the product will work after assembly but how long an item will perform its intended function for a designated period of time without failure under specified conditions.

Design for reliability (DFR) is to avoid issues such as Takata airbag and Microsoft Xbox issues to avoid warranty costs and provide customer satisfaction. Field failures are very costly and can cost billions of dollars in warranties (aside from loss of business and market share). Clearly, in order to be profitable, an organization’s products must be reliable, and reliable products require a formal reliability design process and also designed for quality.

COURSE OBJECTIVES

1. Reduces time-to-market
2. Gain an understanding of the methods, terms and metrics used in reliability, when to apply particular tools during the product development life cycle and the associated benefits and drawbacks of each.
3. Implement a holistic DFR process in product/system design environments and leverage the benefits of this process, namely the Faster, Better, Cheaper values that drive the Reliability 3.0 process.
4. Build an effective reliability culture within the organization and help to determine what needs to be added or improved in your DFR initiatives.
5. Evaluate your strengths in each methodology, which will serve as a guide for any additional skills you may need to acquire or augment.
6. Designing for mistake proofing (poka yoke)
7. The proper techniques to achieving Design for Reliability (DfR).
8. Gain detailed knowledge of designing reliability
9. Understand the concepts of reliability
10. Apply the right tools where is needed
11. Ensure all the requirements are met
12. Understand mathematics of reliability

COURSE CONTENT

1: Design for Quality

1. Affinity Diagram
2. Interrelationship
3. Tree diagram
4. Matrix diagram
5. Matrix data analysis
6. Activity

2: Design for Poka Yoke

1. Poka Yoke, Zero Quality Control
2. The distinctions between judgment inspection, informative inspection and source inspection
3. Predicting where Poka Yokes are needed
4. Examples of everyday Poka Yoke
5. Assembly, Insertion, Inspection, Locating, Mounting, Omissions, Processing and Set Up
6. Poka Yoke evaluation
7. Activity

3: Concept Phase Activities

1. Creating a good DFR plan outlining the sequential activities, and their dependencies
2. Understanding and quantifying environmental and usage conditions and setting reliability requirements and goals

4: Design Phase Activities

1. Risk discovery analysis, change point analysis and design FMEA (DFMEA)
2. Design risk and safety analysis
3. Critical to risk and safety cause mitigation
4. Critical to reliability cause mitigation
5. Design maintainability and supportability analysis
6. Critical to maintainability and supportability cause mitigation
7. Activity

5: Development and Testing Phase Activities

1. FRACAS implementation and usage
2. Component testing, accelerated testing, reliability growth
3. Subsystem, system and field testing

6: Manufacturing Phase Activities

1. Process FMEA (PFMEA)
2. Volume manufacturing and/or supplier control plan

7: Support Phase

1. Field issues, warranty data analysis and forecasting
2. Reliability based diagnostics and repair guides

8: Closing the Loop

1. Communicating, updating and maintaining knowledge items