02.03.13 dfx1 PDF

Design for X
Dr Jane Marshall Product Excellence using 6 Sigma Module

PEUSS 2012/2013 Design for X Page 1
Objectives of the session

Introduce Design for X Discuss Specific Design for X methods
PEUSS 2012/2013
Design for X
Page 2
Design for X
Concurrent engineering is a contemporary approach to DFSS. DFX techniques are part of detail design To improve:
life-cycle cost; quality, increased design flexibility, and increased efficiency and productivity
Benefits include:
competitiveness measures, improved decision-making, and enhanced operational efficiency.
X in DFX is made up of two parts: life-cycle processes x and performance measure (ability) (Huang 1996). Effective approach to implement concurrent engineering. System design
System design
Systems and its characteristics
System is an interrelated set of components, with identifiable boundary, working together for some purpose
A system has nine characteristics:

Components----------------------Subsystems Interrelated components A boundary A purpose An environment Interfaces Input Output Constraints
Design for X Page 4
PEUSS 2012/2013
Environment
Input
Interface Components
Output Boundary
PEUSS 2012/2013 Design for X Interrelationship Page 5
System characteristics
A component
an irreducible part or aggregation of parts that make up a system, also called a subsystem
Interrelated components
Dependence of one subsystem on one or more subsystems
Boundary
The line that marks the inside and outside of a system and that sets off the system form its environment
PEUSS 2012/2013
Design for X
Page 6
Purpose
The overall goal or function of a system
Environment
Everything external to a system that interacts with the system
Interface
Point of contact where a system meets its environment or where subsystems meet each other.
PEUSS 2012/2013
Design for X
Page 7
Constraint
A limit to what a system can accomplish
Input
Whatever a system takes from its environment in order to fulfill its purpose
Output
Whatever a system returns from its environment in order to fulfill its purpose
PEUSS 2012/2013
Design for X
Page 8
Logical and Physical system description

Logical system description
Description of a system that focuses on the system function and purpose without regard to how the system will physically implemented
Physical system description

Description of a system that focuses on the how the system will be materially constructed
PEUSS 2012/2013
Design for X
Page 9
Important system concepts Decomposition Modularity Coupling Cohesion

Decomposition
Is the process of breaking down a system into smaller components in order to:
Focus on one area at a time Concentrate one component pertinent to one group of users Build different components at independent times
PEUSS 2012/2013
Design for X
Page 11
Modularity and Coupling

Modularity
Dividing a system up into chunks or modules of a relatively uniform size. To Simplify the redesign and rebuild process
Coupling
The extent to which subsystems depend on each other. Subsystem should be independent as possible. If one subsystem fails and other subsystem are highly dependent on it, then the other will either fail themselves or have problems functioning
PEUSS 2012/2013
Design for X
Page 12
Cohesion
A cohesion is the extent to which a subsystem performs a single function.
PEUSS 2012/2013
Design for X
Page 13
Design for X tools

Design for Manufacture and Assembly; Design for Reliability; Design for Maintainability; Design for Serviceability; Design for the Environment; Design for Life Cycle Cost; Etc.
Design for X Page 14
PEUSS 2012/2013
Design for manufacture and assembly

Consider during concept stage to reduce cost of redesign later Involvement of manufacturing engineers and supply chain management at concept phase Involve investigating waste Reducing number of standalone parts DFA time identifies cost of assembly and efficiency Investigate alternatives through experimentation Error-proofing poke-yoke
Design for Reliability

Analyse load-strength relationship Design out inherent weaknesses
Analyse potential failure mechanisms and remove or accommodate Analyse potential failure modes past data suppliers history
Plan for reliability improvement Plan correct testing

What is Reliability?
Quality over a period of time The ability of an item to perform a required function under stated conditions for a stated period of time. Reliability is an aspect of engineering uncertainty and therefore measured using probability
Why is reliability important?

Costs of unreliability or unavailability Safety Competitiveness Examples:
Airline costs Automotive reputation Military equipment availability
PEUSS 2012/2013
Design for X
Page 18
Why do products fail?

Design inherently incapable Item overstressed Variation Wear-out Specification, design or coding errors Noise Interaction
PEUSS 2012/2013
How do Products fail?

Discuss how products can fail? Choose different product types and give ideas for how they may fail?
PEUSS 2012/2013
Design for X
Page 20
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Wear-out and Over-stress

OVER-STRESS
Fracture Yield Thermal Electrostatic discharge
WEAR-OUT
Fatigue Creep Erosion Corrosion
PEUSS 2012/2013
Design for X
Page 21
Electronic component failure examples
Mechanical failure
Chip capacitor overstress PCB PTH barrel crack
Solder joint fatigue

PEUSS 2012/2013
Chip resistor
Design for X
BGA active device
Page 22
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Corrosion
Galvanic corrosion
Fretting Corrosion
PEUSS 2012/2013
Design for X
Erosion Corrosion
Page 23
Load and strength

Load - Key Characteristic of interest in environment
Temperature / Pressure Vibration / Humidity
Strength - Key characteristic of interest in manufactured product

Tensile Strength Current Rating Propagation Delay
12
Requirements & Environment - Engine Controls

Typical Civil Engine environment
Temperature extremes
operating non-operating -55 to 100 -65 to 125
FADEC
Reliability Requirements
Vibration extremes
low frequency general blade passing <5g 20g 50g
Typical environment much more benign
Service requirements
Life 25 yrs 100,000 hrs operating
PEUSS 2012/2013(33
Reliability 30,000 hours MTBF failures/million hrs) Design for X
In a Safety Critical Harsh Environment Application

Page 25
Load and strength

Generally failures occur if
Load exceeds Strength
PEUSS 2012/2013
Design for X
Page 26
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Load and strength
Probability
Load
Strength
No overlap of distributed values .. No failures

Load and strength

Failure
Probability
Load
Strength
PEUSS 2012/2013
Design for X
Page 28
14
Over-stress
Load Strength
Stress
Wear-out
Load Strength
Stress
15
Bathtub curve
Hazard function
Useful Life
Time
Infant Mortality
PEUSS 2012/2013 Design for X
Wear Out
Page 31

Aim to maximise reliability during service life by:
Measurement & control of manufacturing quality / screening Optimized design & build process to improve intrinsic reliability Assure no systematic faults present in product Provide sufficient margin to meet life requirements
PEUSS 2012/2013
Design for X
Page 32
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Early - life
Hazard function
Useful Life
Time
Infant Mortality/early life
Wear Out
Page 33
Early Life Failures Environmental Stress Screening

Sometimes called burn-in electronic components Stresses that cause defective production items which pass other tests to fail Normally 100% test but can be done for batches HASS high combined stresses
Test time shorter than ESS Cheaper
17
Early-life failures
Quality in Manufacture
Service Life
e.g. 20 Years
Life Margin
Screening Effectiveness
Reliability Time
Perceived Quality
Life Failures
Early-life failures Too little product screening

Service Life
e.g. 20 Years Screening Effectiveness
Life Margin
Degraded Reliability Increased Low Hour Failures Improved 1st Time Pass Yield
Hazard function
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Early-life failures Too much product screening

Service Life
e.g. 20 Years
Life Margin
Screening Effectiveness
Higher Service Reliability Reduced Low Hour Failures Reduced 1st Time Pass Yield Reduced Life Margin
Screening effectiveness
At what point is Manufacturing Quality measured?
Following screening ? . following x hours in service? Processes optimised to just pass ESS? Quality engineers aware of early life (service) failure?
How well is E.S.S. Effectiveness measured ?

Failures being detected during ESS? What type of failure, at what point and in which test.. ? Optimised cycles, levels,etc ? Measures of performance ?
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Product screening the answer?

Service Life Improved Build Quality
Improved Quality in Manufacture
More Stringent Quality Control Less Reliance on Screening Higher Service Reliability Reduced Low Hour Failures Improved 1st Time Pass Yield Increased Life Margin
PEUSS 2012/2013
Design for X
Page 39
Useful- life
Hazard function
Useful Life
Time
Infant Mortality
Wear Out
Page 40
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Useful- life
Characterised by failures occurring randomly over time Due to non-systematic, minor anomalous process variations, for example:
Marginal design / tolerance build-up Random periods of reduced manufacturing process control Component part batch problems Maintenance induced failure
Minimising failures during useful life

Learning (and using) lessons from current products
Determine those factors that have a significant effect on product reliability by analysing in-service with manufacturing data. Root Cause analysis of service issues enables generic process improvements in design and manufacture
PEUSS 2012/2013
Design for X
Page 42
21
Wear-out
Hazard function
Useful Life
Time
Infant Mortality
Wear Out
Page 43
Wear-out
Characterised by failure mechanisms broadly repeated across a product type, often following a similar period of use. Due to systematic weak links in design / manufacture.
Processes that consistently stress product during Manufacture Design / Selection of inappropriate parts or function Incompatibility between design and manufacturing capability
Not necessarily an end of life issue

Could occur at any point during product life
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Wear-out - solutions
How can systematic problems be detected prior to use ?
Physics of Failure (PoF) analysis, Finite Element Analysis, Design Of Experiments, Reliability Enhancement Testing (RET)
PEUSS 2012/2013
Design for X
Page 45

Design for useful life Design out inherent weaknesses using tools such as:
FMECA Fault tree analysis (FTA) Physics of Failure ESS Finite element analysis Development Testing Data analysis
PEUSS 2012/2013
Design for X
Page 46
23
Product life cycle

Design
FMECA, FTA, PoF,RBD FE,accelerated life test
Development Development Test Use Field data analysis
FRACAS
Test
ESS, Burn-in
Manufacture SPC
Page 47
Design for maintainability

To minimise:
The downtime for maintenance, user and technician maintenance time, personnel injury resulting from maintenance tasks, cost resulting from maintainability features, and logistics requirements for replacement parts, backup units, and personnel
Maintenance actions can be preventive, corrective, or recycle and overhaul

PEUSS 2012/2013
24
Design for serviceability

Ability to diagnose, remove, replace, replenish, or repair any component or subassembly to original specifications with relative ease Poor serviceability produces warranty costs, customer dissatisfaction, and lost sales and market share due to loss loyalty Have serviceability personnel involved in the early stages, as they are considered a customer segment.
Design for the environment

Addresses environmental concerns as well as postproduction transport, consumption, maintenance, and repair The aim is to minimize environmental impact, including strategic level of policy decision-making and design development DFE usually comes with added initial cost, causing an increment of total life cost Economic evaluation is required both for maximum economic benefit and to estimate what the expected financial savings (or losses) will be
25
Design for life-cycle cost

Real cost of the design Includes the associated costs of defects, litigations, buybacks, distributions support, warranty, and the implementation cost of all employed DFX methods Activity-based cost (ABC)* is a method for estimating life-cycle design cost ABC assumes that the design, whether a product, a service, or a process, consumes activities. ABC objective is to identify activities in the design life, and then assign reliable cost drivers and consumption intensities to the activities
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Design for X

Dr Jane Marshall Product Excellence using 6 Sigma Module

Objectives of the session

PEUSS 2012/2013 Design for X Page 3

A system has nine characteristics:

Logical and Physical system description

Physical system description

Important system concepts Decomposition Modularity Coupling Cohesion

Modularity and Coupling

Design for X tools

Design for manufacture and assembly

Design for Reliability

Plan for reliability improvement Plan correct testing

Why is reliability important?

Why do products fail?

How do Products fail?

Wear-out and Over-stress

Electronic component failure examples

Solder joint fatigue

BGA active device

Load and strength

Strength - Key characteristic of interest in manufactured product

Requirements & Environment - Engine Controls

Typical environment much more benign

Reliability 30,000 hours MTBF failures/million hrs) Design for X

In a Safety Critical Harsh Environment Application

Load and strength

Load exceeds Strength

Load and strength

No overlap of distributed values .. No failures

Load and strength

Design for Reliability

Early Life Failures Environmental Stress Screening

Early-life failures Too little product screening

Early-life failures Too much product screening

How well is E.S.S. Effectiveness measured ?

Product screening the answer?

Minimising failures during useful life

Not necessarily an end of life issue

Design for Reliability

Product life cycle

Development Development Test Use Field data analysis

Design for maintainability

Maintenance actions can be preventive, corrective, or recycle and overhaul

Design for serviceability

Design for the environment

Design for life-cycle cost

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