Design for Quality using Six Sigma approach, empowers Design engineers to know upfront the assembly build quality, correctness and completeness of drawings and their tolerances of features and provide inspection using Automated Programming with PAS-CMM

1. Design for Quality:
Achieving 0
Rejection – A
Reality
Natarajan R
Director
EGS India

2. Agenda
• Introduction to Design For Quality – DFQ
• Checklist for DFQ
• Dimensional Management Techniques
• Predicting Assembly Build
• Automating Inspection Process
• Summary
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3. Introduction to DFQ
• What Tolerance to allocate?
• How will the tolerances affect function?
• Will there be any assembly issues?
• What will be the PPM estimates?
• Is it really necessary to tighten tolerances?
• Have I chosen the right tolerance?
• Am I responsible for increasing the product
Cost?
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4. Did You Know?
Only about 60% of new products launched are
actually a success and that for every seven new
product ideas, only four make it to development
— and then only one succeeds.
Source: Winning at New Products: Accelerating the
Process from Idea to Launch - Robert G. Cooper
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5. DFQ: Definition of Paradigm
• Superior Functionality
• Best Fit
• Least Rejections
• Highest Customer Satisfaction
• Consistent Performance
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6. Quality Issues
• Parts not aligning well for a perfect Fit
• Vibration & Noise due to moving parts
• Inconsistent Life & Performance under
Controlled Testing
• Unpredictable Field Failures
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7. Improper Fit
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8. Vibration - Effects
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9. Vibration & Noise
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10. Field Failures
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11. Six Sigma Approach
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12. Design for Six Sigma (DFSS)
• Objective is to Understand the Root
Cause and Eliminate Defects
• Maximize Return on Investment
• Incorporate Processes for
Continuous Improvement
• Enables Gap Analysis of entire
Product Development System
• Addresses Voice of Customer (VOC)
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13. 5 Steps in DFSS
• Plan—enable the team to succeed with the
project by mapping all vital steps
• Identify—hear the voice of the customer to
select the best product concept
• Design—build a thorough knowledge base about
the product and its processes
• Optimize—achieve a balance of quality, cost, and
time to market
• Validate—demonstrate with data that the voice
of the customer has been heard and that
customer expectations have been satisfied
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14. DFSS – Another Perspective
• Define—determine the project goals and the
requirements of customers (external and internal)
• Measure—assess customer needs and
specifications
• Analyze—examine process options to meet
customer requirements
• Design—develop the process to meet the
customer requirements
• Verify—check the design to ensure that it’s
meeting customer requirements
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15. SS Vs DFSS
• DMAIC is more focused on reacting, on detecting
and resolving problems, while DFSS tends to be
more proactive, a means of preventing
problems.
• DMAIC is for products or services that the
organization offers currently; DFSS is for the
design of new products or services and
processes.
• DMAIC is based on manufacturing or
transactional processes and DFSS is focused on
marketing, R&D, and design.
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16. Checklist for DFQ
✔ Is the Drawing Correct?
✔ Is the Drawing Complete with Respect to Functional Tolerancing?
✔ Has Process Capability been incorporated while selecting
Tolerances?
✔ Has Assembly Build Criteria been defined?
✔ Has Interference Analysis been performed?
✔ Have Critical Dimensions for Assembly Build been identified?
✔ Have tolerances been maximized for required Assembly Build?
✔ Have Tolerances been optimized for least cost?
✔ Is the PPM Estimate meeting our Business Profitability Objective?
✔ Is there a Dimensional Verification Plan?
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17. Dimensional Management Techniques
• Develop G D & T / Plus-Minus Tolerancing
Schematic using DimXpert inside SolidWorks
• Perform Assembly Build Analysis using
SigmundWorks inside SolidWorks
• Update SolidWorks Drawing with Optimized
Tolerances
• Establish CMM Inspection Program
automatically from SolidWorks Drawing using
PAS-CMM for SolidWorks
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18. GD&T Vs Plus/Minus Tolerancing
Plus/Minus Tolerancing Geometric Tolerancing
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19. GD&T Drawings using DimXpert
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20. Answers to Quality Challenges
CAD Part Geometry Product Specification
Tooling Geometry Process Capability
Assembly Sequence &
Measurement Plan
Index Plan
Dataset Tolerances, Cost Optimized
Tolerance Cost Drivers
Datum and GD & T Tolerances
PPM Estimation Key Characteristics
Inspection Dimensions Performance
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21. Dimensional Management Plan
• Assured Quality on
adherence to DM Plan
• Eliminates Cost due to
Poor Quality
• Ensures Quality in First
Prototype !
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22. Tolerance Analysis Vs Tolerance Synthesis
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23. Setting Build Objectives
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24. Setting Build Objectives
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25. Defining Node Tree of
Dimensions & Tolerances
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26. PPM Estimates
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27. Identifying Contributors
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28. Incorporating Process Capability
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29. Updating SolidWorks Drawings
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30. Establishing Dimensional Inspection
Process with PAS-CMM
• Automated CMM Programming from 3D CAD Designs
• Reduces CMM Programming time by 90%
• Eliminates ambiguity in drawing interpretation
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31. Summary of Benefits
• Correctness & Completeness of Drawings assured
• Assembly Issues are eliminated
• Maximized Tolerancing for Least Cost
• Identification of Critical Dimensions affecting Assembly
Build & Performance
• Estimate Rejections a priori
• Establish Dimensional Inspection FREE OF ERRORS
• Eliminates customer rejection of parts/ assemblies
• Ensures Consistent Quality
• Reduces/ Eliminates Human errors in subjective
interpretation of drawings that result in re-work, time
delays and escalates product cost
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32. Thank You
Interested in Design for Quality?
Contact: info@egs.co.in
Web: www.egsindia.com www.egs.co.in
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