Quality design of the hottest lean R & D

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The quality of lean research and development raises 168million yuan through stock issuance. Product quality design is regular and a science. It should not only rely on experience to design. Only by building a systematic quality design platform can it maximize its value. By using pera Q can improve the quality design level, so as to improve the inherent quality of products, reduce costs and shorten the product development cycle

according to statistics, the expenses related to quality activities (assurance, testing, rework, repair, return and claim) of Chinese enterprises account for more than 20% of the total business volume. For most manufacturing enterprises, the profit margin is 10% - 20%. Every penny spent on solving quality problems is net profit. It can be seen that the cost of quality has swallowed up a lot of profits of the enterprise. Therefore, only by carrying out scientific and effective product quality design, enterprises can obtain huge profit space. As long as the quality loss is reduced by half, the profit can be increased by 10%

the quality design sub platform (pera.q) of Ansai Asia Pacific is an important part of the lean R & D platform. It plays a role in the whole process of the whole product life cycle, including conceptual design, scheme design, detailed design and prototype experiment. By providing quality processes and methods for the lean R & D platform, enterprises can develop high-quality products. The quality design product architecture is shown in Figure 1

Figure 1 quality design product architecture figure

product development involves three processes: system engineering development, design engineering development and process development. In these three processes, we enter from the lean research and development platform, and use innovative design, collaborative simulation and quality design together. After many iterations, a lean R & D bus is formed, and finally the whole R & D process will accumulate into a R & D knowledge base, thus forming the core competitiveness of enterprise knowledge assets. Only by carrying out scientific and effective quality activities can enterprises obtain huge profit space

the design process determines the product quality

production is to realize the product according to the design drawings and process requirements. The production process cannot solve the unreasonable drawing design or the congenital problems of the design of process parameters. The quality inspection is the Conformity verification after the completion of production, which belongs to the post inspection. The purpose is to pick out unqualified products. It is only a check, but can not improve the product quality. The design process establishes quality standards and determines the inherent quality of products. Once the product is developed, the gene of the product will be determined. It can be seen that quality is designed. To improve product quality, we should start from the source of design. Solving product quality problems in the design process can achieve twice the result with half the effort. The more measures are taken at the front of the product life cycle, the more obvious the effect of improving product quality is

lean R & D application process

quality design methodology

1 Modern product design theory

design is a science. At present, there is a large design theory system, which is very helpful for enterprise design:

(1) European classic design theory: it emphasizes that design is a mapping process, and the realization of function is the transformation of energy and information, which reveals the essence of the design process

(2) innovative design theory of the Soviet Union: innovation has rules to follow. Innovation is not the patent of genius, but something that everyone can learn and master

(3) Japanese robust design theory: it emphasizes that quality should be designed into products, including system design, parameter and tolerance design

(4) axiomatic design theory of the United States: maintain the independence of functional requirements and the principle of minimizing information content, focusing on constructing a complete practical framework for design activities

(5) six sigma Design in the United States: pursue Six Sigma quality and zero defects

the lack of R & D engineers in modern enterprises is not professional technology, but the lack of systematic product development methods to accelerate the product development process and quickly design high-quality products

2. Quality design methodology

puts together three branches closely related to quality, forming the theoretical system of quality design; Namely: robust design theory, six sigma Design and axiomatic design theory. The three have differences and connections, forming a set of practical and effective quality design methods. Quality design is also a science. The goal is to establish a strong product development system and design products with first-class quality, low defects and low cost

(1) axiomatic design theory

axiomatic design theory puts forward an overall axiomatic theoretical framework, which provides a standard to evaluate and judge the quality of product design, and provides methods to improve the quality. Axiomatic design concept proposes: from conceptual design to primary design and then to product design stage, design and mapping step by step, from user domain to functional domain, then to physical domain, and finally to process domain. It provides a series of judgments. In the decomposition of judgments at each level, if there are signs of bad design, it will be nipped in the bud, and the conceptual design problems will not be transferred to the detailed design, and the detailed design problems will be transferred to the process design

(2) robust design

the goal of Japanese robust design theory is to establish a robust development system, so that development engineers, whether experienced or inexperienced designers, can design products with first-class quality, low defects and low cost. Robustness design includes system design, parameter design and tolerance design. The theory puts forward that the quality requirements of customers are decomposed and transformed into design parameters to form the expected target value, and finally we should produce high-quality and low-cost products with stable and reliable performance

(3) six sigma Design (see Figure 2)

Figure 2 six sigma Design Theory

Six Sigma design pursues zero defects, provides relevant tools and methods in the design process, such as QFD, FMEA, etc., and provides design back-end methods, especially in process optimization

PERA. Q quality design process

1 Quality design technology system

pera Q quality design (see Figure 3) includes six core technologies, namely, comprehensive quality deployment, axiomatic design, experimental design, robustness design, reliability design and X-oriented design. These six technologies have complex logical relationships between applications and data. Unified process management, data management and knowledge management are adopted to realize the integration of technology applications. Through multidisciplinary optimization, the comprehensive optimization of the back-end design is realized

Figure 3 pera Q quality design system

2 Quality design application model (see Figure 4)

Figure 4 quality design application model

quality design process

the quality design process starts from the needs of customers, from conceptual design to detailed design to process design, and comprehensively maps the needs of customers. That is, driven by customer needs, realize the level by level expansion of functional and technical reliability and cost, and form a visual design chart

in the process of mapping, axiomatic judgment, experimental design, robustness design, reliability design and X-oriented design are carried out, and finally the virtual prototype of enterprise design is formed, and the quality system and objectives are achieved through the underlying platform. By mapping the needs of customers to the requirements of products and encapsulating various methods into the platform, designers do not need to understand complex mathematical methods, so as to help enterprises easily complete the application of quality design methods. The whole process of quality design is to realize the design and improvement of quality on the basis of ordinary design, and form a virtual digital prototype with high quality and high reliability

(1) comprehensive quality deployment (QFD): solve the problem of how to clarify the design objectives and priorities through product quality planning. Driven by customer needs, realize the level by level expansion of function, technology, reliability and cost, and form a visual design chart. The application of QFD is a process of analysis and deduction of multiple houses of quality. According to the application model of ASI, it is generally required in 2.6 that the motor can be changed separately in four stages. The output of the upper level will automatically become the input of the lower level, so as to realize the mapping and transformation from customer needs to the design objectives, process parameters and control conditions of the first level. The core of QFD is the house of quality, which graphically shows the requirements, technical characteristics, competitive analysis, design objectives and the relationship between them. In this way, the designer will understand what the needs of each process are and what technical means to solve them. Through competitive comparison, the designer will determine the focus of the design, technical bottlenecks and target values. QFD is a front to back deployment system

its value points are:

① it realizes the transformation from the user demand world to the technology world; ② Determine the goals and priorities of the design through value and competition analysis; ③ The visualization of design and development process is realized; ④ The original design information is quickly used, which greatly reduces the development time and design changes

(2) axiomatic design: the analysis and judgment of the overall design scheme in the system design stage mainly solves the problem of systematic irrationality. From the precise mapping of user needs to design parameters, we can quickly analyze and judge the coupling of the system, quantify and evaluate the complexity of the system, and provide a basis for system simplification and innovation, so as to achieve the optimal overshoot system design and effectively promote the modularization and standardization of enterprise design

axiomatic design includes the design method of the whole design process. It is widely used and is closely related to QFD, TRIZ, robust design and DFX

(3) robust design: in the detailed design stage, based on the analysis of test results, the parameters and tolerances are optimized. Robustness puts quality design into products, quantitatively analyzes and determines the best parameters and reasonable tolerances of products, and realizes the design effect of low cost and high quality

(4) orthogonal experimental design (DOE): use the orthogonal table to arrange and analyze the multi factor experimental scheme, select some representative horizontal combinations from all the horizontal combinations of experimental factors for the experiment, understand the comprehensive experimental situation and find out the optimal horizontal combination through the analysis of the experimental results

such a test method can effectively reduce the number of tests, reduce the test cost and shorten the development cycle. In addition to arranging the test plan, the influence degree of factors on quality indicators can also be clarified through the analysis of test data, and the best level of each factor can be determined. Through the level collocation of multiple factors, the best design effect can be achieved

(5) reliability design and analysis (FMEA) (see Figure 5): the reliability allocation and prediction of products are continuous activities in the product R & D process, which are closely combined with the whole R & D process. Through the establishment of product failure information base and failure and impact analysis system, the information feedback mechanism of improvement measures to the superior design link is realized. Through the decomposition and analysis of product reliability indicators, the prediction, distribution, calculation and early warning of reliability indicators are realized to ensure the reliability of the system. FMEA is a feedback system from back to front

comprehensive quality deployment

Figure 5 DFMA application model

(6) design for X (DFX): the core part of DFX is to solve the problems of manufacturability and assembly of the design scheme, that is, DFMA (Design for manufacturing and assembly), which reduces the difficulty of process and production. DFMA core has two points:

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