A BRIEF INTRODUCTION TO THE CONCEPT OF "ROBUST DESIGN"
By Dr.N.Ramani Principal School of Postgraduate Studies NTTF, Bangalore 27.Sep2006
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Analogy between Jungles of Africa & Todays Economy
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Fortune 500?
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In future there will be only two types of Organizations: 1 & 2 ?
Tom Peters
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How?
D C
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How?
Robust Design
D
C
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Q
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Can there be a consumer Product guaranteed for 100 years?
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Can there be a pen which is
Guaranteed for 100 years?
And in addition...
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Can there be a pen which writes
Upside down?
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Can there be a pen which writes
Upside down? Under water?
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Can there be a pen which writes
Upside down? Under water?
Over grease?
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Can there be a pen which writes
Upside down? Under water?
Over grease?
In freezing cold?
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Can there be a pen which writes
Upside down?
Under water?
Over grease? In freezing cold?
Under boiling heat conditions?
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Can there be a pen which writes
Upside down? Under water? Over grease? In freezing cold? Under boiling heat conditions? Used on all manned space flights of Americans & Russians?
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Can there be a pen which writes
Upside down? Under water? Over grease? In freezing cold? Under boiling heat conditions? Used on all manned space flights of Americans & Russians? & Guaranteed for 100 years?
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Fischer Pen Development funded by NASA Patented Pen Construction Sealed pressurized Ink Cartridge With Nitrogen
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Article: Watery Graves of the Maya National Geographic Issue Oct 2003 Pages 83-84
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Fischer pen Anecdote between American & Russian Astronauts
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What makes a two-wheeler sell?
PERFORMANCE?
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What makes a product sell (Say a two-wheeler)?
P-E-R-FORM-AN-CE P = Price E = Economy R = Reliability Form = Aesthetics AN = And CE = Cumulative Effect of all other parameters like... ROBUST DESIGN 25
What do we see here?
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What do we see here?
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What do we see here?
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Quality symbol is inseparable from Cost & Delivery ROBUST DESIGN
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Design?
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What constitutes Design? 1. Assembly For Function 2. Component Construction / Shape / Size 3. Dimensions & Tolerances 4. Features 5. Materials 6. Heat Treatment / Finish Specifications 7. Acceptance procedure...
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DFA
Reason for its importance?
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A =?
Assembly
Aesthetic Appeal
Accessibility
Accessories
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DFA Term coined by Geoffrey Boothroyd
A never ending Process?
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DFB
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DFC
Design for cost
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DFD
Delivery
Dependability
Detail
Duty Cycle
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DFM
Manufacturability Machinability
Heat-treatability Max permissible Tolerance Maintainability Materials Market
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DFS
Design for Simplicity
Case of a long letter
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DFX
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Design For A to Z
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Design For X
DFX = (DFA to DFZ)
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Design For X
Which is the most important X ?
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Which is the most important X ?
Design For X
DFC !?
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Which is the most important X ?
Design For C
Customer designed Car! Expansion of FORD DFT
>>>> DFM !
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Domino Effect
X=
A to Z
Z
Y X
E F
W
V U T S R
DFX
I
H J K
Q Compromise?
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ROBUSTA? MAN-MADE Vs GOD-CREATED DESIGNS?
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QUALITY PARADOX
100% 100%
Knowledge / Expertise of our own product !
Cost of Change !
0% First Proto - Proto -Proto
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0% -Proto Time
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QUALITY PARADOX
100% 100%
Flexibility & Opportunity to improve design quality of a new Product
0% First Proto - Proto
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-Proto
-Proto
0% Time
50
100%
QUALITY PARADOX
100%
Flexibility & Opportunity to improve design quality of a new Product
Knowledge / Expertise
of our own product ! Cost of Change !
0% First Proto - Proto -Proto -Proto
0% Time
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AN ANALOGY OF A RIVER &..
UPSTREAM
DOWNSTREAM
MIDSTREAM
SEA
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AN ANALOGY OF A RIVER & A PRODUCT WRT INFLUENCING ITS QUALITY
UPSTREAM
PRODUCT & PROCESS DESIGN
DOWNSTREAM
CUSTOMER USAGE POST PRODUCTION SERVICE WARRANTY
MANUFACTURING
MIDSTREAM
SEA
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QUALITY CONTROL
OFF - LINE
ON - LINE
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SIGNAL Vs NOISE FACTORS
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Variability is a fact of life
Performance of a product as measured by QC varies in field due to Noise Factors
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Principle of R.D is to maximize Quality by minimizing effects of variation without eliminating causes Achieved by optimizing product to make performance minimally sensitive to causes of variation (Parameter Design)
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A classical Example of Earliest Application
of
Principle of Robust Design
in Japan
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1950 Japan INA Tile Mfg. Co 40% Rejections of Tiles after curing
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Burner
Tiles
Kiln Wall
Schematic Arrangement of Kiln for curing tiles
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Analysis of Problem:
Effect: Variation of Tile dimensions Observation:Tiles at center of Kiln experienced a lower temperature than those at periphery Cause: Non-uniformity of distribution of temperature
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Solution proposed by experts A new modern kiln from USA, assuring uniform temperature distribution
Cost: US$500,000
At high cost also, it made economic sense, because of rejections!
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Robust Design Methodology Application of principles of R.D Eliminate the effects of noise factors, without eliminating noise factors Increase in lime content from 1% to 5% made the dimensional variability dramatically smaller!
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Explanation of Principle of Robust Design
Problem was solved by minimizing the effect of cause of the variation ( Non-uniform temperature distribution) without controlling the cause itself (Kiln Design)
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Cause - Effect Relationship
Input - Output Relationship
Trick is to find out which 20%...
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Principle of R.D is to maximize Quality by minimizing effects of variation without eliminating causes Achieved by optimizing product / process design to make performance minimally sensitive to causes of variation ( Parameter Design)
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3D CAD
Rapid Prototyping of Components
Effective FMEA
Taguchi Technique to decide on the minimum number & treatment combinations of trials required
Rapid Tooling
Rapid Testing
Rapid Design Iteration
Rapid & Robust Design
Design For Assembly
Design For Manufacture
DFX
Relations Diagram on Rapid & Robust Design ROBUST DESIGN
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Thank You
[email protected]
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