The first book to integrate axiomatic design and robust design for a comprehensive quality approachAs the adoption of quality methods grows across various industries, its implementation is challenged by situations where statistical tools are inadequate, yet the earlier a proactive quality system is introduced into a given process, the greater the payback these methods will yield.Axiomatic Quality brings together two well-established theories, axiomatic design and robust design, to eliminate or reduce both conceptual and operational weaknesses. Providing a complete framework for immediate implementation, this book guides design teams in producing systems that operate at high-quality levels for each of their design requirements. And it shows the way towards achieving the Six-Sigma target-six times the standard deviation contained between the target and each side of the specification limits-for each requirement.This book develops an aggressive axiomatic quality approach that: Provides the tools to reduce conceptual weaknesses of systems using a framework called the conceptual design for capability Reduces operational weaknesses of systems in terms of quality losses and control costs Uses mathematical relationships to bridge the gap between science-based engineering and quality methods Acclaro DFSS Light, a Java-based software package that implements axiomatic design processes, is available for download from a Wiley ftp site. Acclaro DFSS Light is a software product of Axiomatic Design Solutions, Inc.Laying out a comprehensive approach while working through each aspect of its implementation, Axiomatic Quality is an essential resource for managers, engineers, and other professionals who want to successfully deploy the most advanced methodology to tackle system weaknesses and improve quality.

BASEM SAID EL-HAIK, PhD, is Director of Textron Six-Sigma and Transformation at Textron Inc., where he is responsible for design of Six-Sigma and Six-Sigma deployment, including Black Belt waves, champions, and projects. He is a coauthor of Design for Six- Sigma: A Roadmap for Product Development. Dr. El-Haik also lectures and researches extensively on axiomatic design, robust design, Six-Sigma, and state-of-the-art quality methods.

Foreword

xiii

Preface

xv

Introduction to the Axiomatic Quality Process

1

(20)

Why Axiomatic Quality?

1

(2)

Goals and Scope of the Book

3

(1)

Axiomatic Design

3

(6)

Six-Sigma and Design for Six-Sigma Philosophy

9

(3)

Introduction to Design for Six-Sigma

11

(1)

Robustness Engineering: Taguchi's Quality Engineering

12

(3)

Problems Addressed by Axiomatic Quality

15

(1)

Introduction to the Axiomatic Quality Process

16

(1)

Axiomatic Quality in Product Development

17

(2)

Summary

19

(2)

Axiomatic Design Method

21

(23)

Introduction

21

(3)

Axiomatic Design Method

24

(5)

Design Domains

25

(2)

Design Hierarchy and Zigzagging Process

27

(1)

Acclaro DFSS Light® ftp://ftp.wiley.com/public/sci_tech_med/axiomatic_quality/

27

(2)

Introduction to the Independence Axiom

29

(1)

Introduction to the Information Axiom

30

(2)

Axiomatic Design Theorems and Corollaries

32

(4)

Axiomatic Design Corollaries

33

(1)

Axiomatic Design Theorems of General Design

34

(2)

Theorems for Design of Large Systems

36

(1)

Case Study: Depth Charge Initiator (Nordlund, 1996)

36

(7)

Summary

43

(1)

Independence Axiom

44

(18)

Introduction

44

(2)

Independence Axiom and the Zigzagging Approach

46

(3)

Coupling Measures

48

(1)

Design Mappings and Design Structures

49

(1)

Case Study 1: Axiomatic Design of a Water Faucet (Swenson and Nordlund, 1995)

50

(5)

Case Study 2: Implementation Methodology for Transition from Traditional to Cellular Manufacturing Using Axiomatic Design (Durmusoglu et al., 2002)

55

(5)

Axiomatically Driven Cellular Manufacturing System

56

(4)

Summary

60

(2)

Information Axiom and Design Complexity

62

(23)

Introduction

62

(2)

Traditional Formulation of the Information Axiom: Suh's Definition

64

(7)

Complexity Reduction Techniques

65

(6)

Complexity Vulnerability

71

(1)

Theoretical Foundation of the New Complexity Theory

72

(2)

New Complexity Theory

74

(3)

Coupled Design Complexity

76

(1)

Complexity Due to Statistical Correlation

77

(6)

Summary

83

(2)

Quality Engineering: Axiomatic Perspective

85

(21)

Introduction

85

(1)

Robust Design (Quality Engineering): Overview

86

(2)

Mathematical Relationship between the Quality Loss Function and Axiomatic Measures

88

(4)

Mathematical Relationship between the Quality Loss Function and Axiomatic Measures of Higher Modularity

92

(10)

Equal Variance

95

(1)

Equal Sensitivity

96

(6)

Estimation of the Expected Loss Function

102

(1)

Mathematical Relationship between the Signal-to-Noise Ratio and Axiomatic Measures

103

(1)

Summary

104

(2)

Axiomatic Quality and Reliability Process

106

(39)

Introduction

106

(2)

Axiomatic Quality Process

108

(7)

Why the Axiomatic Quality Process?

109

(3)

Axiomatic Quality Process Map

112

(2)

Axiomatic Quality Design Team

114

(1)

Customer Attributes-to-FRs Mapping: Understanding the Voice of the Customer

115

(10)

QFD Stage 1

121

(2)

QFD Stage 2

123

(2)

Conceptual Design for Capability Phase

125

(1)

Define FR Specification Target Values and Allowable Tolerances

125

(1)

Option A: Conceptual Design for the Capability Phase of an Incremental Design

126

(9)

Step A.1: Perform the Physical Mapping (Design Analysis)

127

(1)

Step A.2: Perform the Physical Mapping (Design Synthesis)

128

(3)

Step A.3: Uncouple or Decouple the Design Mappings

131

(1)

Step A.4: Conduct Axiomatic Quality Concept Selection

131

(1)

Step A.5: Detail the Structures

132

(1)

Step A.6: Prepare for the Optimization Phase of the Structure Selected

133

(2)

Option B: Conceptual Design for the Capability Phase of a Creative Design

135

(3)

Step B.1: Define the Pursuit Ideal Product

135

(1)

Step B.2: Understand and Project Product Evolution

136

(1)

Step B.3: Initial Concept Generation

137

(1)

Axiomatic Quality Optimization Phase

138

(1)

Axiomatic Quality Process Deployment

139

(6)

Axiomatic Quality Process Concept Selection Process

145

(26)

Introduction

145

(2)

Design Feasibility in Axiomatic Quality

147

(4)

Modules

147

(1)

Design Technical (Morphological) Feasibility

148

(3)

Concept Selection Problem

151

(4)

Concept Selection Fuzzy Modeling

155

(5)

Fuzzy Concepts

155

(1)

Possibility--Probability Consistency Principle

156

(1)

Maximum Entropy Formulation

157

(3)

Axiomatic Quality Fuzzy Concept Selection Formulation

160

(10)

Case Study: Global Commercial Process

161

(9)

Summary

170

(1)

Conceptual Design for the Capability Phase

171

(30)

Introduction

171

(1)

Problems That Can Be Solved by Axiomatic Quality

172

(1)

Conceptual Design for the Capability Phase

173

(8)

Implication of Coupling in the CDFC Phase

174

(3)

Step A.3: Uncouple or Decouple the Design Mappings

177

(4)

Case Study: Transmission Vane Oil Pump CDFC

181

(11)

Pump Zigzagging Process

183

(6)

Decoupling Phase

189

(1)

Step A.5: Detail the Design

190

(2)

Theory of Inventive Problem Solving

192

(5)

TRIZ in the Axiomatic Quality Process

194

(3)

Summary

197

(4)

Appendix 8A: Design Matrixes

197

(4)

Axiomatic Quality Optimization Phase

201

(32)

Introduction

201

(2)

Axiomatic Quality Operational Vulnerability Optimization

203

(6)

Vulnerability Optimization Routine

205

(4)

Parameter Design Optimization

209

(9)

Noise Factors Identification

210

(1)

Parameter Design Optimization DOEs

211

(1)

Data Collection and Results Analysis

212

(1)

Case Study: Axiomatic Quality Parameter Design

213

(5)

Axiomatic Quality Strategy in the Tolerance Optimization Phase

218

(6)

Robustness at Six-Sigma Quality: Signal-to-Noise Ratio and Quality Loss Function

219

(5)

Design Operational Vulnerability Optimization Using Tolerances of Uni-FR Design Modules

224

(4)

Coupling Vulnerability Constraint

226

(1)

Meaning of the Solution

227

(1)

Design Operational Vulnerability Optimization Using Tolerances of an FR Array

228

(3)

Summary

231

(2)

Appendix 9A: Proof of Theorem 9.1

231

(2)

Case Study: Low-Pass Filter Axiomatic Quality Process

233

(10)

Introduction

233

(1)

Problem Statement

234

(1)

Passive Filter Conceptual Design for the Capability Phase

235

(3)

Passive Filter Tolerance Optimization Phase

238

(5)

Axiomatic Reliability

243

(30)

Introduction

243

(2)

Why Axiomatic Reliability?

245

(1)

Axiomatic Reliability in the Development Cycle

246

(1)

Axiomatic Reliability in the Design Stages

247

(13)

Linear, Independent, Uncoupled Design

256

(2)

Linear, Independent, Decoupled Design

258

(2)

Case Study: Passive Filter Design

260

(5)

Physical Structure Axiomatic Reliability Formulation

265

(4)

Time-Dependent Physical Structure Axiomatic Reliability Assessment

267

(2)

Physical Structure Axiomatic Importance Formulation

269

(1)

Structured Modules

269

(1)

Design for Reliability

270

(2)

Summary

272

(1)

References

273

(8)

Index

281

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