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Full Description
This book integrates key tools and processes into a comprehensive program for developing more robust and reliable technology-based products. Drawing on their extensive product development experience, the authors present a complete process for ensuring product performance throughout the entire lifecycle, from understanding customers' needs through manufacturing and post-launch support.The authors begin by presenting broad insights and high-level strategies for improving product quality. Next, they demonstrate how to implement robustness and reliability strategies that complement existing governance and decision processes. A section on tools and methods shows how to institutionalize best practices and apply them consistently. Finally, they tie strategies, decisions, and methods together through a case study project.Product developers will learn how toUnderstand critical drivers of value in technology products, including reliability and durability Implement a process model and roadmap for improving reliability and robustness Increase robustness early in development, leading to shorter cycle times in later phases Improve the stability of production performance under stress conditions Assess both organizational and process capabilities for delivering robust and reliable products Understand and manage customer-driven requirements Use tools including descriptive and inferential statistics and DOE-based empirical modelsManagers will understand expectations forDesign concepts supported by rigorous analyses of alternatives Products and processes delivering higher value to customers Products with higher reliability and longer useful lives Product processes with lower costs and higher capabilities Development projects having shorter, more predictable cycle timesReaders are introduced to many thought leaders whose writings can be sources of further learning. This book is a valuable resource for anyone responsible for delivering reliable, profitable technology products, including general managers, program managers, engineers, scientists, and reliability and quality professionals.
Contents
Preface xxiAcknowledgments xxixAbout the Authors xxxiSection I: Critical Drivers of ValueChapter 1: Time, Money, and Risks 3Quality, Costs, and Schedules 4Management of Process Improvements 7Soft Causes of Poor Reliability and Durability 12Key Points 20Discussion Questions 20Chapter 2: Reliability, Durability, and Robustness 21Reliability as an Element of Value to Customers 22Essential Elements of Reliability 23The Taxonomy of a Failure 26Reliability Metrics 29The Anatomy of Quality Loss 33The Reduction of Performance Variations 39Key Points 44Discussion Questions 44Chapter 3: Strategies for Reliability Development 45Are Better Strategies Important? 45Strategies for Ongoing Processes 48Strategies Specific to Product Development 51Capabilities of the Organization 57Key Points 63Discussion Questions 63Section II: Framework for Reliability DevelopmentChapter 4: A Process Model for Product Development 67What Is a Product Development Process? 67Integration of Key Development Principles 71A Process Model for Product Development 76Advanced Product-Planning Process 77Technology Development Process 79Product Development Process 81Older versus Better Methods 98Key Points 100Discussion Questions 100Chapter 5: Road Map for Reliability Development 103Build a Compelling Case for Your Reliability Project 103Linking Activities to the Product Development Phases 104Key Initiatives of a Reliability Development Project 104The Role of Testing 116Key Points 119Discussion Questions 119Chapter 6: Effective Decisions 121Qualities of a Good Decision-Making Process 122Types of Project Reviews 132Key Points 144Discussion Questions 145Chapter 7: Robustness Development for Product Designs 147Technology and Product Development 147Functional Diagram 150Stressful Conditions 151Parallel Development of Products and Processes 155Robustness Development 158Examples of Robustness Development 162Robust Design 165Robustness Development Fixtures 167Key Points 168Discussion Questions 169Chapter 8: Reliability Growth and Testing 171Product Testing 172Reliability Growth Testing 174Drivers of Reliability Growth Rate 181Accelerated Tests 183Understanding Stress versus Strength 185Tools and Systems That Support Testing 190Overview of Various Types of Tests 196Key Points 197Discussion Questions 197Section III: Tools and Methods Supporting Reliability DevelopmentChapter 9: Understanding and Managing Customer-Driven Requirements 201Objectives for Product Development 202Types of Requirements 203How Requirements Affect Project Success 206How Requirements Flow Down 213VOC Activities Vary Throughout the Development Process 214The Major Steps in Requirements Gathering 215Processing and Analyzing Interview Data 221Key Elements of Requirements Management 227How Can Your Requirements Efforts Fail? 228Key Points 229Discussion Questions 230Additional Reading 230Additional Authors Worth Following 230Chapter 10: Quality Function Deployment 231What Is Quality Function Deployment? 231Expected Benefits of QFD 233The Structure of QFD 234Sequence of Matrices 244The QFD Team 245Suggestions to Improve the Facilitation of QFD 246Key Points 247Discussion Questions 248Further Reading 248Chapter 11: Concept Generation and Selection 249Decisions in Product Development 249Concept Generation and Selection 250Process Guidance 256Teamwork 259Key Points 260Discussion Questions 260Chapter 12: Axiomatic Design 261Axiomatic Design 262Improvement of Design Concepts 272System Decomposition 274A Familiar Example 279Key Points 282Discussion Questions 282Chapter 13: Tools to Reduce Risks 285Project Team Meetings for Risk Reduction 285Useful Tools Provide Valuable Benefits 286Risk Analyses 289Matrix Analyses 294Flowcharts 296Tree Analyses 301Key Points 307Discussion Questions 307Further Reading 307Chapter 14: Descriptive Statistics 309Why Do You Need Statistics? 309Graph the Data First 310Descriptive Statistics 322The Normal Distribution 325Key Points 329Discussion Questions 329Chapter 15: Inferential Statistics 331Questions You Need Statistics to Help Answer 331Population versus Samples 332The Power of Averaging 333Making Comparisons and Assessing Progress 335Hypothesis Testing, Confidence Intervals, and p-Values 339Equivalence Testing 364Some Concerns with Significance Tests 368Key Points 369Discussion Questions 370Chapter 16: Building Models Using ANOVA and Regression 371Uncovering Relationships and Proving Cause and Effect 371Empirical Models 375ANOVA 376Model Building Using Regression 380Summary 391Key Points 392Discussion Questions 393Chapter 17: Building Empirical Models Using DOE 395Overview of DOE 395Important Questions to Answer before an Experiment 400Important Questions to Answer after Running the Experiment 404Some Important Considerations 406Types of Experiments 409Sequential Approach to Experimentation 412A Simple Example 412Key Points 414Discussion Questions 415Chapter 18: Developing System Robustness Using DOE 417Using System Models and Noise to Improve Robustness 417Robustness Optimization of the Machining Process 421Additional Options for Optimization 426Key Points 429Discussion Questions 429Chapter 19: Robustness Optimization Using Taguchi's Methods 431Taguchi's Contributions to Robust Design 431Building a Detailed Model versus Improving System Robustness 433Signal-to-Noise Ratio (S/N) 437Example Problem 440Key Points 452Discussion Questions 454Chapter 20: Tolerance Optimization 455The Tolerance Design Problem 455Controlling Variability 458How Do Tolerances Affect Product Performance? 459Steps for Tolerance Design 462Tolerances and the Cost of Quality 464Analysis of Tolerance Stacks 466Optimization of Functional Responses 474Key Points 477Discussion Questions 477Chapter 21: Reliability Functions and Life Distributions 479Fundamental Reliability Functions 479Useful Life Distributions 483Key Points 493Discussion Questions 494Chapter 22: Life Data and Their Implications 495Sources of Life Data 495Competing Failure Modes, Mixtures of Life Distributions, and the Importance of Failure Analysis 496Preventive Maintenance of Repairable Systems 499Fitting a Life Distribution to a Data Set 501Accelerated Life Testing (ALT) 506Mixed Failures from Time and Actuations 510Key Points 512Discussion Questions 512Section IV: Integration of Framework and MethodsChapter 23: Critical Parameter Management 515CPM and the Domains of Product Development 515Linking Customer Satisfaction and Critical Parameters 519Assessing Difficulty 522Assessing Importance 525Critical Parameters and Risk 528Critical Parameter Measurement 531CPM: A Process for Creating, Using, and Maintaining Information 532Key Points 532Discussion Questions 533Chapter 24: An Illustration of Process Methods and Tools 535Advanced Product Planning 536Product Development 538Epilogue 559Chapter 25: Balancing Schedules, Budgets, and Business Risks 561Ongoing Attention to Product Development Capabilities 563Be a Student of the Process 572Glossary 573Bibliography 585Index 593
