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ROBUST DESIGN 1
A BRIEF INTRODUCTION TOTHE CONCEPT OF
"ROBUST DESIGN"
By Dr.N.Ramani
Principal
School of Postgraduate Studies
NTTF, Bangalore 27.Sep2006
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ROBUST DESIGN 2
Analogy between Jungles of Africa &
Todays Economy
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ROBUST DESIGN 3
Fortune 500?
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ROBUST DESIGN 4
In future there will be only two typesof Organizations: 1 & 2 ?
Tom Peters
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ROBUST DESIGN 5
Q
C
D
How?
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ROBUST DESIGN 6
Robust Design
Q
C
D
How?
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ROBUST DESIGN 7
Can there be a consumer Product
guaranteed for 100 years?
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ROBUST DESIGN 8
Can there be a pen which is
Guaranteed for 100 years?
And in addition...
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ROBUST DESIGN 9
Can there be a pen which writes
Upside down?
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ROBUST DESIGN 10
Can there be a pen which writes
Upside down?
Under water?
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ROBUST DESIGN 11
Can there be a pen which writes
Upside down?
Under water? Over grease?
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ROBUST DESIGN 12
Can there be a pen which writes
Upside down?
Under water? Over grease?
In freezing cold?
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ROBUST DESIGN 13
Can there be a pen which writes
Upside down?
Under water?
Over grease?
In freezing cold?Under boiling heat conditions?
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ROBUST DESIGN 14
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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ROBUST DESIGN 15
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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ROBUST DESIGN 16
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ROBUST DESIGN 17
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ROBUST DESIGN 18
Fischer Pen Development funded byNASA
Patented Pen Construction
Sealed pressurized Ink Cartridge
With Nitrogen
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ROBUST DESIGN 19
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ROBUST DESIGN 20
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ROBUST DESIGN 21
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ROBUST DESIGN 22
Article:
Watery Graves ofthe Maya
NationalGeographic
Issue Oct
2003
Pages 83-84
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ROBUST DESIGN 23
Fischer pen Anecdote betweenAmerican & Russian Astronauts
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ROBUST DESIGN 24
What makes a two-wheeler sell?
PERFORMANCE?
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ROBUST DESIGN 25
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...
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ROBUST DESIGN 26
What do we see here?
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ROBUST DESIGN 27
What do we see here?
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ROBUST DESIGN 28
What do we see here?
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ROBUST DESIGN 29
Quality symbol is inseparable from Cost &
Delivery
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ROBUST DESIGN 30
Q
C
D
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ROBUST DESIGN 31
Design?
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ROBUST DESIGN 32
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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ROBUST DESIGN 33
DFA ?
Reason for its importance?
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ROBUST DESIGN 34
A =?
Assembly
Aesthetic Appeal
AccessibilityAccessories
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ROBUST DESIGN 35
DFA
Term coined by Geoffrey BoothroydA never ending Process?
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ROBUST DESIGN 36
DFB ?
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ROBUST DESIGN 37
DFC ?
Design for cost
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ROBUST DESIGN 38
DFD ?
Delivery
Dependability
Detail
Duty Cycle
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ROBUST DESIGN 39
DFM ?Manufacturability
Machinability
Heat-treatability
Max permissible Tolerance
MaintainabilityMaterials
Market
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ROBUST DESIGN 40
Design for SimplicityCase of a long letter
DFS ?
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ROBUST DESIGN 41
DFX ?
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ROBUST DESIGN 42
Design For A to Z
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ROBUST DESIGN 43
Design For X
DFX = (DFA to DFZ)
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ROBUST DESIGN 44
Design For X
Whichis the most important X ?
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ROBUST DESIGN 45
Design For X
Which is the most important X ?
DFC !?
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ROBUST DESIGN 46
Design For C
Which is the most important X ?
Customer designed Car!
Expansion of FORD
DFT >>>> DFM !
Domino Effect X = A to Z
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ROBUST DESIGN 47
DFX
A B CD
EF
G
H
I
JK
LM
NOP
QR
S
T
U
V
WX Y
Z
Domino Effect X A to Z
Compromise?
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ROBUST DESIGN 48
ROBUSTA?
MAN-MADE Vs GOD-CREATED
DESIGNS?
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ROBUST DESIGN 49
QUALITY PARADOX
0%
100%
Knowledge /
Expertise of our
own product !
0%
First
Proto
- Proto -Proto -Proto Time
100%
Cost of Change !
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ROBUST DESIGN 50
QUALITY PARADOX
Flexibility &
Opportunity to
improve design quality
of a new Product
0%
100%
First
Proto
- Proto -Proto -Proto Time
100%
0%
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51First
Proto
Flexibility &
Opportunity
to improvedesign
quality of a
new Product
0%
100%
Knowledge /
Expertise
of our own product !
- Proto -Proto -ProtoTime
100%
0%
Cost of Change !
QUALITY PARADOX
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ROBUST DESIGN 52
UPSTREAM
MIDSTREAM
DOWNSTREAM
SEA
AN ANALOGY OF A RIVER&..
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ROBUST DESIGN 53
AN ANALOGY OF A RIVER & A PRODUCT
WRT INFLUENCING ITS QUALITY
CUSTOMER USAGE
POST PRODUCTION
SERVICE WARRANTY
UPSTREAM
MIDSTREAM
DOWNSTREAM
SEA
PRODUCT &PROCESS
DESIGN
MANUFACTURING
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ROBUST DESIGN 54
QUALITY CONTROL
OFF - LINE
ON - LINE
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ROBUST DESIGN 55
SIGNAL Vs NOISE FACTORS
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ROBUST DESIGN 56
Variability is a fact of life
Performance of a product as measuredby QC varies in field due to NoiseFactors
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ROBUST DESIGN 57
Principle of R.D is to maximize Quality by
minimizing effects of variation withouteliminating causes
Achieved by optimizingproduct to make performance minimally
sensitive to causes of variation (Parameter
Design)
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ROBUST DESIGN 58
A classical Example
of
Earliest Application
of
Principle of Robust Design
in Japan
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ROBUST DESIGN 59
1950
Japan
INA Tile Mfg. Co
40% Rejections of Tilesafter curing
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ROBUST DESIGN 60
Schematic Arrangement of Kiln for curing tiles
Burner
Kiln Wall
Tiles
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ROBUST DESIGN 61
Analysis of Problem:
Effect: Variation of Tile dimensions
Observation:Tiles at center of Kiln
experienced a lower temperaturethan those at periphery
Cause: Non-uniformity of
distribution of temperature
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ROBUST DESIGN 62
Solution proposed by experts
A new modern kiln from USA,assuring uniform temperature
distributionCost: US$500,000
At high cost also, it madeeconomic sense, because ofrejections!
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ROBUST DESIGN 63
Robust Design Methodology
Application of principles of R.D
Eliminate the effects of noise
factors, without eliminating noisefactors
Increase in lime content from 1% to5% made the dimensional variabilitydramatically smaller!
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ROBUST DESIGN 64
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ROBUST DESIGN 65
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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ROBUST DESIGN 66
Cause - Effect Relationship
Input - Output RelationshipTrick is to find out which 20%...
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ROBUST DESIGN 67
Principle of R.D is to maximize Quality by
minimizing effects of variation withouteliminating causes
Achieved by optimizingproduct / process design
to make performance minimally sensitive
to causes of variation ( Parameter Design)
Rapid
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ROBUST DESIGN 68
Rapid & RobustDesign
RapidPrototyping
ofComponents
Rapid Tooling
Taguchi Technique todecide on the minimumnumber & treatment
combinations of trialsrequired
Rapid Testing
Relations Diagram on Rapid & Robust Design
EffectiveFMEA
DesignFor
Assembly
Design ForManufacture
3D CAD
DFX
Rapid DesignIteration
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Thank You
pgschool@nttf co in
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