Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why...

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KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org www.build4scale.org

BetaPrototypeandTestPlanModule4AKeyQues(ons

KeyQues(onsU.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY www.build4scale.org

o Manyhardwareinnovatorsexcelatcrea(ngtechnically-viablealphaprototypes,butlosecustomerandinvestorconfidencebyintroducingseveralfailedversionsofbetaprototypesbeforecommercializingtheirproduct

o Abasicunderstandingofhowtoreducethenumberofvaria(onsofbetaprototypessaveshardwareinnovatorsvaluable(meandmoney

Whyisthismoduleimportant?Mo1va1on

BetaPrototypeAndTestPlanWheredoesthisfitintothedevelopmentcycle?

ConceptandFeasibility Defini1on Productand

ProcessDesignImplementandValidate

Produc1onandStock

LaunchandClosure

Pre-alpha Alpha Beta Pilot Ramp Scale

BUILDS

EngineeringValida9on

DesignValida,on

ProcessValida,on

ConceptValida9on

PRODUCTDESIGNOBJECTIVESMarketResearch

DesignResearchFeasibility

DevelopmentQualifica1on

FieldReadinessLaunch

ManufacturingCapacity

MANUFACTURINGREADINESSLEVELSLevels: 109987654321

MfgDevelopmentManufacturingResearch

MfgCapability

Produc(on

(MRLs)ManufacturingReadinessLevels

MaterialSolu1onsAnalysis TechnologyDevelopment EngineeringandManufacturingDevelopment

Produc1onandDeployment

Opera1onsandSupport

BasicmanufacturingImplica(onsIden(fied

ManufacturingConceptsIden(fied

ManufacturingProofofConceptdeveloped

Capabilitytoproducethe

technologyinalaboratoryenvironment

Capabilitytoproduceaprototypecomponents

inaproduc1onrelevant

environment

Capabilitytoproduceaprototypesystemor

subsysteminaproduc1on-relevant

environment

Capabilitytoproducesystems,

subsystemsorcomponents

inaproduc1on-relevant

environment

Pilotlinecapability

demonstrated.Readytobegin

low-rateproduc(on

LowRateProduc(on

demonstrated.Capabilityinplacetobegin

FullRateProduc(on

demonstratedandleanproduc(onprac(cesin

1 2 3 4 5 6 7 8 9 10

Thismodule’scontentisrelevantattheseMRLs

Pre-alpha Alphaprototypes Beta

prototypes Pilotprototypes

o Learningobjec(veso Differencebetweenalphaandbetaprototypeso Designforfailuremodeandeffectsanalysis(DFMEA)— Whatitisandhowtouseittoyourbenefit

o Manufacturingresources

ModuleOutline

o LO1.Whatarethekeyques(onstoconsiderwhendesigningandtes(ngabetaprototype?

LearningObjec1ves

o Whatistheexpecta(onofthecustomer,industry,ormarketformyproduct?

o WhatamIdesigningmyproductfor(e.g.,durability,serviceability)?

o Whatarethemostcommonmistakestoavoid?o HowdoIavoidthedevelopmentofseveralprototypemodifica(ons?

o WheredoIgoforprototypingservices?o Whoarethemanufacturingexpertsthatcanhelpmethroughthisprocess?

KeyQues9onsWhatThisModuleAddresses

o Developingaproductwithoutconsideringhowtodesignforitsopera(ngenvironment

o Launchingaproductwithoutdesigningforpoten(alfailuremodes

o Focusingonlowcostandspeedtomarketovercarefuldesignqualitymanagementanddesignformanufacturing

o Over-designingtheproductandfailingtoachievemarginspredicted

o Fallingintothetrapofredesigningaproductmul(ple(mes,whichaddstoproductdevelopmentcoststhatexhaustcompanyfundinganddelaysproductintroduc(ontomarket

Tobesuccessfulyourproductmustbeunique,butyourmanufacturingprocessshouldnotbe!

Commonmistakesandmisconcep9onsBetaPrototypeAndTestPlan

Therearetwotypesofalphahardwareprototypes:o A“looks-likeprototype”thatprovidesinsighttoergonomicsandaesthe(cs

o A“works-likeprototype”thatdemonstrateskeyfunc(onalelements

o Alphahardwareprototypesareodenconsideredtobe“labexperiments”thatarenotnecessarilydesignedforthecommercialrequirements/environments

o Theydemonstratewhattheproductiscapableofdoing

BasicsAlphaHardwarePrototype

o Alphahardwareprototypesusekeyfeaturesofthehardwareproducttoallowpeopletointeractwithitsfunc(onalityandproposedsolu(on

o Theyareusedtoprovethatcorefeaturesoftheproductworkinadevelopmentortes(ngenvironmentunderidealcondi(ons

Basics(cont.)AlphaHardwarePrototype

o Betahardwareprototypesareamorepolishedversionofthekeyfeaturesofthehardwareproduct;theycanbeuseddirectlybyacustomer

o Theyarebuiltwiththeintenttoprovethatpeoplewantthesolu(onbydemonstra(ngitinthecommercialrequirements/environments— Theyareusedtoprovethatcorefeaturesworkforasmallsetofcoopera(ngbetacustomersunderless-than-idealcondi(ons

BasicsBetaHardwarePrototype

o Betahardwareprototypesareusedtoelicitcustomerfeedbackandgatheraddi(onaldatarela(ngtousageandfeaturesneededtobeabletosupporttweakingtheproductbeforeproductlaunch— Theycanberunprivatelyorthroughahandpickedsetofcustomersand/orstrategicpartners

o Theydemonstratethefinishedproduct,exceptforanyimportantcustomerrequirementsthathavenotyetbeendiscovered

Basics(cont.)BetaHardwarePrototype

o Companydescrip1on:Thehybridrivetweldtechnologycombinestheadvantagesofself-piercerive(ngwithresistancespotweldinginjoiningofdissimilarmaterials(aluminumtosteel)

o Companytype:— Product— Material— ManufacturingProcess— ManufacturingService— ManufacturingOpera(ons

Casestudy1-RivetweldjoiningAlphatoBetaPrototype

sheet-to-cast

composites

sheettotube

cross-section

highstrengthsteel

Source:Op9malProcessTechnologies

Casestudy1-Rivetweldjoining(cont.)

TechnologyReadinessLevel

Basicprinciplesobservedandreported

Technologyconceptand/orapplica(onformulated

Proofofconcept

analyzedandexperimented

Componentorsystem

valida(oninlab

environment

Systemvalida(on,tes(nginopera(ng

environment

Prototype/pilotsystemverifica(oninopera(ng

environment

Fullscaleprototypeverifiedinopera(ng

environment

Actualsystemcompleteandfunc(oninginopera(ng

environment

Actualsystemtestedanddatacollectedoverlife(meofsystem

1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year1progress

Proofofconcept

Componentorsystem

valida(oninlab

environment

1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year1progress

Year2progress

o Whenatestfailsatareadinesslevel,thereisaneedtoretreatbackwards(odenbacktwolevels)

Example:IfthefullscaleprototypefailstobeVerifiedinOpera(ngEnvironment(MRL7),youhavetogobacktoMRL5totestopera(ngenvironments

Proofofconcept

Componentorsystem

valida(oninlab

environment

1 2 3 4 5 6 7 8 9

BasicTechResearch

FeasibilityResearch

TechDevelopment

TechDemonstra1on

SystemCommissioning

SystemOpera1on

Year3Retreat

Year1progress

Year2progress

Ififfails….

Casestudy1-Rivetweldjoining(cont.)ManufacturingReadinessLevels

MaterialSolu1onsAnalysis TechnologyDevelopment EngineeringandManufacturingDevelopment

Produc1onandDeployment

Opera1onsandSupport

BasicmanufacturingImplica(onsIden(fied

ManufacturingConceptsIden(fied

ManufacturingProofofConceptdeveloped

Capabilitytoproducethe

technologyinalaboratoryenvironment

Capabilitytoproduceaprototype

componentsinaproduc(onrelevant

environment

Capabilitytoproducea

prototypesystemorsubsystemina

produc(on-relevant

environment

Capabilitytoproducesystems,

subsystemsorcomponentsinaproduc(on-relevant

environment

Pilotlinecapabilitydemonstrated;readytobegin

low-rateproduc(on

LowRateProduc(on

demonstrated;capabilityinplacetobeginFullRate

Produc(on

FullRateProduc(on

demonstratedandleanproduc(on

prac(cesinplace

1 2 3 4 5 6 7 8 9 10

ImaginethisprototypeiscurrentlyatmanufacturingreadinessMRL4andfacesthefollowingDFMorscaleupchallenges:q Some,butnotall,joiningsamplesmetcustomerqualityspecifica(ons

o Processnotrepeatableandnotprovenonavarietyofmaterialso Toomuchcustomizedtoolingo Poorunderstandingofcosttradeoffsofproposedprocessvs.exis(ngproduc(onprocesses

o Equipmentnotop(mizedformassproduc(on(automatedmaterialhandling,robo(cs)

o NoqualitycontrolmeasurementWhatac(onscanbetakentoaddressthechallengesabove?

AlphatoBetaPrototype

Ac1onsthatcanbetakentoaddresstheMRL4challengesonpriorslideinclude:o Designforquality:adoptedin-situweldassurancetes(ngtoensurequality

o Designforcustomerrequirements:includeddemonstra(onsonawidevarietyofmixedmaterials(Al,Mg,HSS)

o Designforcost:reducedcustomizedtoolingandalignedwithexis(ngproduc(onprocesses

o Designforreliability:usedFEA/CFDmodelingtoop(mizerivetshapeandjoiningprocess

o Designfortakt1me:includedautomatedrivetfeeder,integratedwithautoma(onequipment

AlphatoBetaPrototype

o Howwillthebetaprototypebeevaluatedbythecustomer?

o Whatfeatures/func(onsaremust-haves,nice-to-haves,orarenotthatimportanttothecustomer?

o Whatarethetypicalexpecta(onsforproductperformanceanddurability?

o Howmusttheproductoperate?o Howwilltheproduct’sperformanceandqualitybeevaluated?

o Whattes(ngisrequiredbeforemyproductwillbeconsideredforpurchasebythecustomer?

o CanIsimulateproductinopera(ontopredictperformancebeforeinves(nginphysicalprototype?

Whatdoesthecustomer,industry,ormarketexpectofmyproduct?

KeyQues1ons

o Designformanufacturability— CanIreduceBOM,materialtradeoffs,costreduc(ons?

o Designforassemblyandmanufacturingprocess— CanIreduceprocesssteps,labor?— CanIreducecapitalequipment,toolingcosts?— CanIreducescrap,improveyield?

o Designfordurability,designforopera(ngenvironment— HaveIconsiderednoise/vibra(on/harshnesstes(ng,loadingcondi(ons,engineerforlife(me?

WhatamIdesigningmyproductfor?KeyQues1ons

o Designformaintenanceserviceability— CanIdesigninservicecostreduc(ons?

o Designforpackaging— HaveIconsideredproductprotec(on,shippinglogis(cs,transporta(oncosts?

o Designforsustainability— CanIreducewastematerials,scrap,allowforrecyclability,usebiodegradablematerials?

o Designforcustomerusability— CanIdesigntomakeiteasytouseformycustomer?

WhatamIdesigningmyproductfor?(cont.)

KeyQues1ons

Lifecycle:o Howlongdoesmyproductneedtolast?o Whatdoesmyproductwarrantyneedtocover?o Whatistheexpecta(onofthecustomer?Customerusability:o Howwillmyproductbehandledbythecustomer?o Howwillitbeservicedifitrequiresmaintenanceandrepair?Logis1cs:o HowdoIneedtocareformyproductininventory?o Whatistheshelflifeofmyproduct?o Howwillmyproductbetransported?

Otherconsidera9onsKeyQues1ons

o Productprocesscostsarenotpredictableo Limitedpar(cipa(onorcoordina(onfromateamperspec(veo Launchismorereac(vethanproac(veo Takestoolongtolaunchtheproducto Notachievingthepredictedmarginso Overlookinglowestcostop(onsforproduc(onandassemblyo Toodependentonlowercostoverseaspartnersforqualitymanagement

o Over-promisingandunder-delivering

Commonmistakesandmisconcep9onsProductLaunch

o Productisengineeredwell,butcannotbeproducedo Productispoorlyengineeredbecauseadvancedsimula(ontoolswerenotused(FEA/CAE)

o Productisover-engineeredo Productmustbecompletelyredesignedo Failuretorethinkproductdesigntodriveoutcosto Productcostoverruns(i.e.,toolingandcapitolequipmentcosts)

Commonmistakesandmisconcep9onsProductDesign

o Processcannot“runatrate”asexpectedo Failuretoplanforeveryparto Poorpartqualityo Failuretoreduceopera(onscostsandwasteo Failuretoimprove,measure,ortrackqualityo FailuretoproperlymanageinventoryofinboundBOMoroutboundfinished-productstock

o Encounteringcapacityconstraintso Requiringmorespaceornewbuildingtoaccommodatenewsales

o Over-inves(nginopera(onsandrunningatlowcapacityrates26

Commonmistakesandmisconcep9ons

ProductProcess

Mistakesmade:o Introducedtheproductsixteenmonthslaterthanoriginal(meline

o Sole-sourcedsuppliersandranintopartsshortageswhensupplierscouldn’tdeliver

o Tookshortcutsonqualityinspec(onofbakerypackso Finalcostofvehiclewas$20,000/carmorethantheoriginaltargetprice

o Didnotdesignproductfordurabilityandexperiencedmul(plefailuresinthefield

Caststudy2–Start-upelectricvehiclecompanyDevelopingBetaPrototypes

Impact:o Companymarginswerenega(veonfirstvehiclelaunch

o Angeredpre-orderdepositcustomersbynotdeliveringvehiclebydateadver(sed

o Warrantycostskyrocketedwhenbakeriesfailedandside-impactcrashesledtolegalseklements

o Exhaustedinvestorfundsandfiledforbankruptcy

Caststudy2–Start-upelectricvehiclecompany(cont.)

DevelopingBetaPrototypes

Bestprac1ces:o Mi(gatedthecostriskbydevelopingadisciplinedapproachtocosttarge(ngfortheen(revehicleBOM

o Controlledproductop(onsandvaria(ons

o Mi(gatedsupply-chainrisksbysecuringmul(plesourcesofsuppliersforeachpart

o Mi(gatedqualityriskbyimplemen(ngDFMandcostupfrontwithinternalteamsandexternalsupplypartners

DevelopingBetaPrototypesCaststudy2– Start-upelectricvehiclecompany(cont.)

Bestimpact:o Companymarginswereposi(veonfirstvehiclelaunch

o Pre-orderdepositcustomershadtheirvehiclesdeliveredon(me

o Limitedfailuresexperiencedinthefield,whichcontrolledwarrantyandrecallcosts

o Receivedfollow-oninvestorfundstolaunchnewvehicleplamorms

Caststudy2–Start-upelectricvehiclecompany(cont.)

Casestudy3–LEDlampDevelopingBetaPrototypes

Whatistheexpecta1onofthecustomer,industry,ormarketformyproduct?o WorkingoffofB1-A,marketfeedbackwasconductedwithassistancefromindustrialdesignfirmpriortoprototypeitera(on,interviewingstakeholders(fieldcrews,distributors,u(lityexecu(ves).Theproductexpecta(onisanindustrialgradeLEDlamp,designedforuseinoutdoorstreetligh(ngcondi(ons.Thewarrantyrequirementsformunicipalcustomersodenare10years,meaningdurabilityandreliabilityarekeydecidingfactors.Therearealsominimumoutputandefficiencyrequirements,whicharequitehighgiventhestateofcurrentLEDtechnology.Thismeanstheproductmustusehighqualitycomponentswhilekeepingcostslow.

Product:B1-aandB1-b

WhatamIdesigningmyproductfor?(inorderofpriority)o Performance(lightqualitymeasuredinlumensdelivered)o Energyefficiency(measuredinlumenoutputperwakforthetotaldeliveredsystem)

o Reliability(reliabilitytoexceed10yearwarrantyrequirement)o PriceWhatarethecommonmistakestoavoid?o Spendingtoomuch(meintheweedstryingtominimizethecostofeverycomponentintheBOM.Iden(fythecorecomponentsthatdriveBOMandfocusonop(mizingthose.Forthiscasestudy,theLEDpackagingwasmostimportant. 32

Casestudy3–LEDlamp(cont.)

Product:B1-aandB1-b

HowdoIavoidthedevelopmentofseveralprototypemodifica1ons?o Makeextensiveuseofcomputersimula(onstovalidateheattransferperformanceofvariousdesignitera(onspriortogoingtophysicalprototype

o Implementdesignformanufacturingsoonerintheengineeringanddesignprocess.Thisiswheretheindustrialdesignfirmaddedalotofvalue,asinnovatorsareodenunabletoseethemanufacturingimplica(onlandminesearlyon(chassisdesignsthatwouldop(mizeforextrusionvs.stampingprocesses).

Product:B1-aandB1-b

o Theindustrialdesignfirmhadthein-housecapabili(estocreatemostofthecomponentpartsthatwereneededtomaketheproofofconceptprototype(3-Dprin(ng,CNCmachiningcapabili(es,etc.)

WheredoIgoforprototypingservices?o DFMconsul(ngfirms(suchasDragonInnova(on)o Industrialdesignfirmso Independentconsultants

Product:B1-aandB1-b

o HowdoIdesignnowtoavoidmistakesinthefuture?o HaveIconsideredallpoten(alfailuremodes?o Whatarethepoten(aleffectsofthosefailures?o Whatarethelikelycausesorreasonsforthosefailures?o Whatisthelikelihoodofoccurrenceandseverityofeachfailuremode?

Recommenda9on:Hardwarecompaniesandinnovatorsshouldins(tuteDesignforFailureModeandEffectsAnalysis*(DFMEA)asapartoftheirBetaPrototypePlans(seenextpage)

HowdoIavoidthedevelopmentofseveralprototypemodifica9ons?

KeyQues1ons

*Adaptedfrom“QualityTrainingPortal:19StepstoConductaDFMEA”www.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm

o Designforfailuremodeandeffectsanalysis(DFMEA)isahighlystructured,systema(cproduct-designmethodologyforpre-evalua(ngpoten(alproduct

o DFMEAisodenthefirststepofaproduct-orprocess-reliabilitystudy;itinvolvesreviewingasmanycomponents,assemblies,andsubsystemsaspossibletoiden(fyfailuremodes,andtheircausesandeffects

o Foreachcomponentorprocess,thefailuremodesandtheirresul(ngeffectsontherestofthesystemarerecordedinaspecificDFMEAworksheet

DesignforfailuremodeandeffectsanalysisFailureModeAndEffectsAnalysis

1.  Reviewthedesign:Useablueprintorschema(cofthedesign/producttoiden(fyeachcomponentandinterface

2.  Brainstormpoten(alfailuremodes:Reviewexis(ngdocumenta(onanddataforclues

3.  Listthepoten(aleffectsoffailure:Theremaybemorethanoneforeachfailure

4.  Assignseverityrankings:Basedontheseverityoftheconsequencesoffailure

5.  Assignoccurrencerankings:Basedonhowfrequentlythecauseofthefailureislikelytooccur

Step-by-stepConductADFMEA

6.  Assigndetec(onranking:Basedonthechancesthefailurewillbedetectedpriortothecustomerfindingit

7.  Calculatetheriskprioritynumber(RPN):SeverityxOccurrencexDetec(on

8.  Developtheac(onplan:Definewhowilldowhatbywhen9.  Takeac(on:Implementtheimprovementsiden(fiedbyyour

DFMEAteam10. Calculatetheresul(ngRPN:Re-evaluateeachofthepoten(al

failuresonceimprovementshavebeenmadeanddeterminetheirimpactontheRPNs

Step-by-step(cont.)ConductADFMEA

o Ensurethatallteammembersarefamiliarwiththeproductanditsdesign

o Iden(fyeachofthemaincomponentsofthedesignanddeterminethefunc(onorfunc(onsofthosecomponentsandinterfacesbetweenthem

o StudyallcomponentsdefinedinthescopeoftheDFMEAo Useaprintorschema(cforthereviewo Addreferencenumberstoeachcomponentandinterfaceo Tryoutaprototypeorsampleo Inviteasubjectmakerexperttoanswerques(onso Documentthefunc(on(s)ofeachcomponentandinterface

Step1-Reviewthedesign

ConductADFMEA

o Reviewdocumenta(onforcluesaboutpoten(alfailuremodesbeforeundertakingbrainstormingsessions

o Usecustomercomplaints,warrantyreports,andreportsthatiden(fythingsthathavegonewrong(i.e.,holdtagreports,scrap,damage,andrework)asinputs

o Considerwhatmayhappentotheproductunderdifficultusagecondi(onsandhowtheproductmightfailwhenitinteractswithotherproducts

Step2-Brainstormpoten9alfailuremodes

ConductADFMEA

o Considerpoten(alfailuremodesforeachcomponentandinterface

o Apoten(alfailuremoderepresentsanymannerinwhichtheproductcomponentcouldfailtoperformitsintendedfunc(onorfunc(ons

o Manycomponentswillhavemorethanonefailuremode.Donotleaveoutapoten(alfailuremodejustbecauseitdoesnothappenoden.Documenteachone.

Don’ttakeshortcutshere;thisisthe9metobethorough

Step2-Brainstormpoten9alfailuremodes(cont.)

ConductADFMEA

o Aneffectoffailureisdefinedastheimpactofafailureonasystemshoulditoccur

o Theeffectisrelateddirectlytotheabilityofthatspecificcomponenttoperformitsintendedfunc(on

o Somefailureswilleffectcustomers,otherseffecttheenvironment,theproduct-produc(onprocess,andtheproductitself

Step3– Listpoten9aleffectsoffailure

ConductADFMEA

o Theseverityrankingscaleiscri(caltothesuccessofDFMEAsbecauseitestablishesthebasisfordeterminingtheriskofonefailuremoderela(vetothatofanother— Severityrankingisbasedonarela(ve(notanabsolute)scalerangingfrom1–10(10meanstheeffecthasadangerouslyhighseverity,leadingtoahazardwithoutwarning;1meanstheseverityisextremelylow)

— ExampleformscanbefoundintheFMEAResourceCenter:hkp://www.qualitytrainingportal.com/resources/fmea/index.htm(ledcolumn,underFormsandCheckLists);FMEA’sseverityrankingscale:hkps://qualitytrainingportal.com/resources/fmea-resource-center/?sec(on=generic-severity-ra(ng-scale

o TheDFMEArankingscaleshouldbeusedconsistentlythroughoutanorganiza(on;thisenablescomparisonoftheRPNsofdifferentDFMEAStooneanother

Step4– Assignseverityrankings

ConductADFMEA

o Thebestwaytocustomizearankingscaleistostartwithagenericscaleandmodifyittobemoremeaningfultoyourorganiza(on

o Byaddingorganiza(on-specificexamplestotherankingdefini(ons,DFMEAteamswillhaveaneasier(meusingthescales;usingexamplessaves(meandimprovestheconsistencyofrankingsfromteamtoteam

o Asyouaddspecificexamples,consideraddingseveralcolumnswitheachcolumnfocusedonatopic.Onetopiccouldprovidedescrip(onsofseveritylevelsforcustomersa(sfac(onfailuresandanotherforenvironmental,health,andsafetyissues.Remember,though,thateachrowshouldreflectthesamerela(veimpactorseverityontheorganiza(onorcustomer.

Step4– Assignseverityrankings(cont.)

ConductADFMEA

o Thepoten(alcausemustbeknowninordertodeterminetheoccurrencerankingbecause,justastheseverityrankingisdrivenbytheeffect,theoccurrencerankingisafunc(onofthecause

o Theoccurrencerankingisbasedonthelikelihood,orfrequency,thatthecause(ormechanism)offailurewilloccur

o Ifthecauseisknown,itiseasiertoiden(fyhowfrequentlyaspecificmodeoffailurewilloccur

o Theoccurrencerankingscale,liketheseverityrankingscale,isarela(vescalerangingfrom1–10

Step5– Assignoccurrencerankings

ConductADFMEA

o Anoccurrencerankingof10meansthefailuremodeoccurrenceisveryhigh;ithappensallofthe(me(conversely,a1meanstheprobabilityofoccurrenceisremote)

o SeeFMEA’sFormsandChecklistswebpageforanoccurrencerankingscaleexample

o Yourorganiza(onmayneedtodevelopacustomizedoccurrencerankingscaletoapplytodifferentlevelsorcomplexi(esofdesign;itisdifficulttousethesamescaleforamodulardesign,acomplexdesign,andacustomdesign

o Someorganiza(onsdevelopthreedifferentoccurrencerankingscales((me-based,event-based,andpiece-based)andselecttheonethatappliestothedesignorproduct

Step5–Assignoccurrencerankings(cont.)

ConductADFMEA

o Toassigndetec(onrankings,considerthedesignorproduct-relatedcontrolsalreadyinplaceforeachfailuremodeandthenassignadetec(onrankingtoeachcontrol

o Thinkofthedetec(onrankingasanevalua(onoftheabilityofthedesigncontrolstopreventordetectthemechanismoffailure

Step6–Assigndetec9onrankingsConductADFMEA

o Detec(oncontrolsiden(fythecauseoffailure,themechanismoffailure,orthefailuremodeitselfaderthefailurehasoccurred,butbeforetheproductisreleasedfromthedesignstage— Adetec(onrankingof1meansthechanceofdetec(ngafailureisalmostcertain,whereasa10meansthedetec(onofafailureormechanismoffailureisabsolutelyuncertain

— ToprovideDFMEAteamswithmeaningfulexamplesofdesigncontrols,consideraddingexamples(edtothedetec(onrankingscalefordesign-relatedtopicssuchasdesignrules,designforassemblyanddesignformanufacturability(DFA/DFM)issues,andsimula(onandverifica(ontes(ng

— SeeFMEA’sFormsandChecklistswebpageforexamplesofcustomDFMEArankingscales

Step6–Assigndetec9onrankings(cont.)ConductADFMEA

o Preven(oncontrolsarealwayspreferabletodetec(oncontrols— Preven(oncontrolscomeindifferentformsandlevelsofeffec(veness

— Preven(oncontrolspreventthecauseormechanismoffailure(orthefailuremodeitself)fromoccurring;theygenerallyimpactthefrequencyofoccurrence

Step6–Assigndetec9onrankings(cont.)ConductADFMEA

o TheRPNprovidesarela(veriskranking;thehighertheRPN,thegreaterthepoten(alrisk— Sinceeachofthethreerela(verankingscalesrangesfrom1–10,theRPNwillalwaysbebetween1and1,000;theRPNisanexcellenttoolforpriori(zingfocusedimprovementefforts

o TheRPNiscalculatedbymul(plyingthethreerankingstogether:theseverityranking,theoccurrenceranking,andthedetec(onranking;calculatetheRPNforeachfailuremodeandeffectNote:ThecurrentAIAGFMEAManualsuggestsonlycalcula(ngtheRPNforthehighesteffectrankingforeachfailuremode.Wedonotagreewiththissugges(on.Webelievethatifthissugges(onisfollowed,itwillbetooeasytomisstheneedforfurtherimprovementonaspecificfailuremode.

Step7–Calculatetheriskprioritynumber(RPN)ConductADFMEA

o Takingac(onmeansreducingtheRPNo TheRPNcanbereducedbyloweringseverity,occurrence,ordetec(onindividuallyorincombina(onwithoneanother

o Areduc(onintheseverityrankingforaDFMEAisodenthemostdifficulttoakain—itusuallyrequiresadesignchange

o Reduc(onintheoccurrencerankingisaccomplishedbyremovingorcontrollingpoten(alcausesormechanismsoffailure

o Areduc(oninthedetec(onrankingisaccomplishedbyaddingorimprovingpreven(onordetec(oncontrols

o WhatisconsideredanacceptableRPN?Theanswerdependsontheorganiza(on.

Example:Anorganiza(onmaydecidethatanyRPNaboveamaximumtargetof200presentsanunacceptableriskandmustbereduced.Ifso,anac(onplan(whowilldowhat,bywhen)isneeded. 51

Step8–Developtheac9onplanConductADFMEA

DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on:o Designofexperiments(DOE)— Powerfulsta(s(calimprovementtechniquesthatcaniden(fythemostcri(calvariablesinadesignandtheop(malsewngsforthosevariables

o Mistake-proofing— Techniquesthatcanmakeitimpossibleforamistaketooccur,reducingtheoccurrencerankingto1

— Par(cularlyimportantwhentheseverityrankingis10

Step8–Developtheac9onplan(cont.)ConductADFMEA

DFMEAtoolstoreducetherela1veriskoffailuremodesrequiringac1on(cont.):o Designforassemblyanddesignformanufacturability(DFA/DFM)— Techniquesthathelpsimplifyassemblyandmanufacturingbymodularizingproductsub-assemblies,reducingcomponents,andstandardizingcomponents

o Simula(ons— Simula(onapproachesincludepre-produc(onprototypes,computermodels,acceleratedlifetests,andvalue-engineeringanalyses

Step8–Developtheac9onplan(cont.)ConductADFMEA

o Theac(onplanoutlinesthestepsneededtoimplementthesolu(on,includingwhowillperformthemandwhentheywillbecompleted

o Asimplesolu(ononlyrequiresasimpleac(onplan,whileacomplexsolu(onrequiresmorethoroughplanninganddocumenta(on;mostac(onplansiden(fiedduringaDFMEAwillfallunderthesimple“who,what,andwhen”category

o Responsibili(esandtargetcomple(ondatesforspecificac(onstobetakenareiden(fied

o Anac(onplanmaytriggeralarge-scaleproject.Ifthathappens,conven(onalprojectmanagementtools(includingPERTChartsandGankCharts)willberequiredtokeeptheac(onplanontrack.

Step9–Takeac9onConductADFMEA

o Bycalcula(ngtheresul(ngRPN,thisstepinaDFMEAconfirmsthattheac(onplanhasproducedthedesiredresults

o TorecalculatetheRPN,reassesstheseverity,occurrence,anddetec(onrankingsforthefailuremodesadertheac(onplanhasbeencompleted

Step10–Recalculatetheresul9ngRPNConductADFMEA

Casestudy4– Automo9vebodystructuresDFMEA

o Joiningdissimilarmaterialsprocessestoproducelighterweightcars

Exercise–DFMEAworksheetBetaPrototypeQualityPlan

o QualityTrainingPortal:10stepstoconductaDFMEAhkp://www.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm

o ChartItNow:DFMEAtemplatehkp://www.char(tnow.com/DFMEA-Template.html

o QIMacros:FMEAtemplateinExcelhkps://www.qimacros.com/lean-six-sigma-ar(cles/fmea-template/

o Systems2win:FMEAtemplatehkp://www.systems2win.com/solu(ons/FMEA.htm

o DMAICTools:PFMEA(defini(onsandexplana(ons)hkps://www.dmaictools.com/dmaic-analyze/pfmea

DFMEA/PFMEAResources

o TechShop:Sharedmanufacturingspacehkp://www.techshop.ws/o Makerspace:Sharedmanufacturingspacehkp://makerspace.sp.edu.sg/

o QuickParts:3Dprin(ngservicehkp://www.3dsystems.com/quickparts

o R&DTechnologies:3Dprin(ngservicernd-tech.com

o Protolabs:3Dprin(ng,CNCmachining,injec(onmoldingservicewww.protolabs.com

o Make(me:CNCmachiningservicewww.make(me.io

o RapidManufacturing/Vaupell:Prototypesheetmetal,machinedparts,cablingservicehkps://rapidmanufacturing.com/

o CircuitHub:OndemandPCBmanufacturingservicehkps://circuithub.com/

Sharedassetfacili9es/prototypingservicesManufacturingResources

Iden1fyregionalsuppliermatchmakingandconnec1onprograms.Examplesinclude:o GreentownLabsManufacturingIni(a(ve,aBoston-areaclean-technologyhardwareincubatorpartnershipwithMassachuseksManufacturingExtensionPartnership(MassMEP)hkp://www.greentownlabs.com/wp-content/uploads/2015/02/020515-Manufacturing-Ini(a(ve-PDF1.pdf

o InnoState,aMichiganentrepreneur-manufacturermatchmakingprogramorganizedbyMEPMichiganManufacturingTechnologyCenter(MMTC)hkp://innostatemi.com/

o PureMichiganBusinessConnect,amatchmakingportalwithlis(ngofeventshkp://www.michiganbusiness.org/grow/pure-michigan-business-connect/ 60

HowdoIfindmanufacturingexperts?ManufacturingResources

o Gettoknowyourlocalmanufacturingextensionpartnership(MEP)

o Secureamanufacturingexpertasanadvisor,evenifitmeansprovidingsomeequity

o Takeadvantageofre(redandsemi-re(redmanufacturingexpertswhoareodeneagertosharetheirexperienceandknowledgewithinnovatorsandstartups

Recommenda9onsFindingManufacturingExper1se

Notsolici9nghelpfrommanufacturingexpertsisacommonmistake!

o SocietyofManufacturingEngineers(SME)ToolingU:Extensiveon-linemanufacturingtraininghkp://www.tooling.com/

o SMEManufacturingInsights®Videoshkp://www.sme.org/mi/

o SMEFundamentalManufacturingProcesses(FMP):44videosonmajormanufacturingprocesseshkp://www.sme.org/fmp/

o SMEDFMATraininghkp://www.toolingu.com/ilt/915101/Design-for-Manufacturability-and-Assembly-DFMDFA

o AdviceManufacturingProcesses:Shortvideosonarangeofcommonmanufacturingindustryprocesseshkp://www.advice-manufacturing.com/Manufacturing-Processes.html

DFXTrainingResources

ManufacturingResources

o TheManufacturingIns(tute:Manufacturingskillscer(fica(onprogramshkp://www.themanufacturingins(tute.org/Skills-Cer(fica(on/Cer(fica(ons/NAM-Endorsed-Cer(fica(ons.aspx

o AMEAlliance:8-weekmanufacturingcer(fica(oncourseshkp://amealliance.org/8-week-cer(ficates

o AlisonIns(tute:Onlinemanufacturingtrainingclasseshkps://alison.com/learn/manufacturing

o DfRSolu(ons:Designformanufacturingtrainingprogramswww.dfrsolu(ons.com

o ElectronicsManufacturingTraininghkp://www.ipc.orgo ManufacturingSkillsTrainingProgramshkp://scien(fic-management.com/skills-training-programs

DFXTrainingResources(cont.)

o Munro&Associates:Leandesignmanufacturingop(miza(ontraininghkp://leandesign.com/lean-design/

o Munro&Associates:Designprofitmanufacturingcos(ngsodwarehkp://www.designprofit.com/

o Ricardo:Productdevelopment,engineeringandmanufacturingtraining,andconsul(nghkp://www.ricardo.com/en-GB/What-we-do/knowledge/Training/

o SocietyofAutomo(veEngineers(SAE):DFM,DFAtraininghkp://training.sae.org/seminars/92047/

o Tec-Ease,Inc.:DesignforassemblyandGD&Ttraininghkp://www.tec-ease.com/design-assembly.php

o EngineersEdge:DFMAtraininghkp://engineersedge.com/training_engineering/design-for-manufacturing-training.htm

DFXTrainingResources(cont.)ManufacturingResources

o OMNEX:DFMAtraininghkp://www.omnex.com/training/rd_Series/design_manufacturing_assembly.aspx

o SSA:DFMAtraininghkp://www.ssa-solu(ons.com/training-program/design-for-manufacturing-assembly.php

o ManufacturingQualityTrainingASQwww.asq.orgo Automo(veIndustryAc(onGroup’s(AIAG’s)AdvancedProductQualityPlanning(APQP)(availableviacoursesoron-line)hkp://www.aiag.org/store/training/details?CourseCode=ELCTO

o TUDeld/UNEP:Designforsustainabilityhkp://www.d4s-sbs.org/o SurfaceMountTechnologyAssocia(on(SMTA):Onlinemanufacturingtrainingcourseswww.smta.org

o SixSigmaU:Designforsixsigmatraininghkp://www.6sigma.us/design-for-six-sigma-dfss.php

o NPDSolu(ons:Designformaintenanceandserviceabilityworkshopshkp://www.npd-solu(ons.com/featuredworkshops/dfsws

o DragonInnova(ons:BOMdevelopmenttoolshkps://www.dragoninnova(on.com/dragon-standard-bom

o GreentownLabsandMassMEP:Bestprac(cesfortrainingstartupstoworkwithmanufacturershkp://greentownlabs.com

o Invent@NMU:Hardwareentrepreneuracceleratorprogramfocusedonaccelera(ontomarketthroughDFXprincipalshkp://www.nmu.edu/invent/home

o Connec(ngGreenTechnologyEntrepreneurs:Buildingconnec(onsforgreentechnologyentrepreneurshkps://www.infodev.org/infodev-files/connec(ng-green-technology-entrepreneurs-full.pdf

o E2byShoptech:All-in-onemanufacturingsodware(quo(ng,accoun(ng,produc(on,inventory,etc.)www.shoptech.com

o BasicCADtools:Autodesk’sFusion360hkp://www.autodesk.com/products/fusion-360

o BasicCADtools:SolidWorkswww.solidworks.com

o GeometricGlobal:Designformanufacturingsodwarehkp://info.geometricglobal.com/design-for-manufacturing-sodware

o Design-IV:DFM/DFAsodwarehkp://www.design-iv.com/

DFXTrainingResources(cont.)

ManufacturingTrainingNetworkResourceso U.S.DepartmentofEnergy’sOfficeofEnergyEfficiencyandRenewableEnergy(EERE)hkp://energy.gov/eere/office-energy-efficiency-renewable-energy

o U.S.DepartmentofEnergy’sAdvancedManufacturingOffice(AMO)hkp://energy.gov/eere/amo/advanced-manufacturing-office

o Na(onalNetworkofManufacturingIns(tutes(NNMIs)hkp://manufacturing.gov/nnmi/ins(tutes.html

OtherManufacturingResources

Wheretolookforaddi1onalresourcesonline:o UniversityandU.S.na(onallaboratorymanufacturingwebsitesandtrainingprograms

o Exis(ngdesignformanufacturabilitytrainingresources(e.g.,SME)

o ManufacturingExtensionPartnerships(MEPs)programshkp://www.nist.gov/mep/

o Hardware-basedincubatorsandacceleratorso Entrepreneurialmentorshipandexpert-in-residence(EiR)programs

o Entrepreneurialcontractmanufacturingmatchmakingprograms

Other(cont.)ManufacturingResources

o DragonInnova(onBlog,September8,2016:Top10ManufacturingReasonsHardwareCompaniesFailhkp://blog.dragoninnova(on.com/2016/09/08/1414/

o MForesightReportManufacturing101:AnEduca(onandTrainingCurriculumforHardwareEntrepreneurs(downloadablePDFfile)hkp://mforesight.org/download/5107/

o MMTCProduc(onPrepara(onProcess(3P)hkps://www.the-center.org/Our-Services/Opera(onal-Excellence/Lean/Produc(on-Prepara(on-Process-(3P)

o Wikipedia:Failuremodeandeffectsanalysishkps://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis

o QualityTrainingPortal:19stepstoconductaDFMEAwww.qualitytrainingportal.com/resources/fmea/fmea_10step_dfmea.htm

References

Glossary

Module 4A

Development is the systematic use of scientific and technical knowledge to meet specific

objectives or requirements.

Qualification is either the process of qualifying for an achievement, or a credential attesting to

that achievement.

Field Readiness is the stage of development just prior to final launch. It is time to review the Pilot run and determine if there are any “game stopper” issues.

Prototype is an early sample, model, or release of a product built to test a concept or process or to act as a thing to be replicated or learned from

Manufacturing Rediness Level (MRL) is a measure developed by the United States Department of Defense (DOD) to assess the maturity of manufacturing readiness

Beta Prototype and Test Plan Prototype and Test Plan Module 4A Key Ques(ons Key Ques(ons ... 2 Why...

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