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TEAM 06
Aniruddha Srinath
Ketan Bapat
Pulkit Agrwal
Syed Rehan Ahmed
MFG599: DESIGNING IN QUALITYA DESIGN FOR SIX SIGMA COURSE
Drake Droplets
Agenda• Project Overview- Mr. Ketan
• IDD-Identify- Mr. Rehan
Project Charter
Project Plan
Project Prioritization Matrix
Customer requirement
• IDD-Define- Mr. Aniruddha
Voice of Customer-CTS Matrix
Kano Analysis
House of Quality
Design Scorecard
• IDD-Design- Mr. Pulkit
Benchmarking, lateral thinking & TRIZ
Design Alternatives
Pugh Matrix
Final Design Concept
IDD – Project Overview
• Product: Refrigerator
• Target market: United States
• Target customers: Family
IDD – Project CharterProject Charter
Project Information Resources
Project #: Grn-Ref-12-01 Champion 1 Aniruddha Srinath
Project Name: Refrigerator Champion 2 Ketan Bapat
Project Start Date: 8-Feb-12 Champion 3 Pulkit Agarwal
Project End Date: 21-Feb-12 Champion 4 Rehan Syed
Problem Statement:
Goal Statement:
Project Scope
Our company ( a multi-product conglomerate) has recently adapted a new sustainability policy which requires all it's
divisions to reform their businesses towards creating and selling environment-friendly products. Since the release of freons
from refrigerators is a big debate in the environment world, our company has specifically asked the refrigerators division to
come up with new green solutions
The goal of this project is to design a "Green Refrigerator" with reduced greenhouse emission ( kg per kilowatt hour), lower
electricity bills ($ ), high reliability (number of years without service) and warranty rates (number of complaints per year)
This project will focus on developing a new referigerator. We will focus on the functional aspects of the case, specifically the
referigerant gases emission and the power consumption and also improve the performance in terms of reliability and
durability.
IDD – Project Plan
8 9 10 11 12 13 14 15 16 17 18 19 20 21
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan
Actual
Plan ∆
Actual
Plan ∆Actual ∆Plan ∆Actual
Working Schedule-Referigerant Project
Define- Kano Matrix
Aniruddha
Aniruddha
Aniruddha
Aniruddha
Rehan
Rehan
Rehan
Identify-Project
Prioritization Matrix
5.b
4.a
4.b
Report making
Design- Final Concept
Pulkit
Pulkit
Ketan
Ketan
3.d
pulkit
Pulkit
4.c
4.d
5.a Presentation preparation
Presentation co-
ordination
3.a
3.b
3.c
1.a
1.b
1.c
2.a
2.b
2.c
5.c
Team
Team
DescriptionEvent
February
Design- Benchmarking &
TRIZ
Design- Design
Alternatives
Design- Pugh Matrix
Define-House of Quality
Define- Design Scorecard
Identify- Project Plan
Job Allocation
Customer Requirements
Define- CTS Matrix
Introduction and job
responsibility allocation
Problem desrciption &
assumptions
Identify- Project Charter
Team
Ketan
IDD – Project Prioritization MatrixGR-Green Referigerants
Be
st
so
luti
on
/ ro
ot
ca
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kn
ow
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Pro
ble
m a
dd
res
se
d
els
ew
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re?
So
luti
on
ou
tsid
e t
ea
m
me
mb
er
co
ntr
ol?
Po
ten
tia
l C
on
tra
dic
tio
ns
w/ O
the
r P
roje
cts
?
Im
pro
ve
s c
om
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ny
ima
ge
Im
pro
ve
s C
om
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Pro
fita
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ity
Ma
y b
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om
ple
ted
wit
hin
Tim
ing
Go
als
Re
lati
ve
ly L
ow
In
ve
stm
en
t C
ost
# Project Name Y/N Y/N Y/N List #Rating (1..5)
5 4 2 2Hard
Savings
Soft
Savings
1 Reduce CFC emissions by 10% N Y N 7,8 9 1 3 1 57 2 $XX $XX
2 Reduce power consumption by 15% N Y N 8 9 3 3 3 69 1 $XX $XX
3 Eliminate electric shock Y Y N 9 1 1 1 53 4 $XX $XX
4 Reduce EMF to less than 50 v/m N N Y 1 1 3 1 17 8 $XX $XX
5Improve reliability (no of hours
before repair)N Y N 3 3 3 3 39 5 $XX
6 Reduce warranty claims by 15% N Y N 5 3 3 3 3 39 5 $XX $XX
7 Reduce cost by 15% N Y N 1,2,5,6,8 3 9 1 1 55 3
8 Increase storage capacity by 20% N Y N 7 1 3 1 1 21 7 $XX
Estimated
Annual Savings,
$$
Selection Criteria
Se
lecti
on
Cri
teri
a R
ati
ng
s
(Lo
w=
1;
Me
diu
m=
3;
Hig
h=
9)
Project FILTERS (Y/N)?
Pro
ject
Pri
ori
ty
Ra
nk
IDD – Customer Requirements
Customer Survey/Focus Group
Sampling
21 Families
Voice of Customers-CTS Matrix
Customer RequirementsKano
Classification
Customer
Importance
Rating
CTS Metric CTS Goal
Is safe to use Basic 4no of
accidents/year0
No odor Basic 5 yes/no No
Easy to clean Basic 3 time in minutes <30 mins
Long time freshness of food Basic 4 yes/no Yes
Has long life Excitement 3 MTBF >7 years
Have temperature control Excitement 2 have/not have have
Door Inbuilt water dispenser Excitement 2 have/not have Have
Fast chilling for making ice cubes Excitement 2 have/not have Have
Has high warranty Excitement 4 no of years >3
Has adjustable compartments Revealed 5 yes/no yes
More number of compartments Revealed 4 nos 15
Costs less to purchase Revealed 3 price in $ <1450
Is environment friendly Revealed 3CFC emission
(kg/hr)<0.5
Have automatic features Revealed 2 yes/n yes
IDD – Kano Analysis
• Kano Analysis:
– Table below summarizes must be, one-dimensional, and delighters
• Potential Delighter – Automatic control features
– Survey sample size was 21
IDD – Kano Analysis Result
House of Quality
Design Scorecard
Benchmarking Analysis:
Adjustable Shelves Water Purifier Eco-friendly (low CFC emissions) Rapid Ice making
• Lateral Thinking:
Provocative Statement: We are no longer using refrigerator as standalone unit.
TRIZ Contradiction Analysis:1.
Feature Trying to Improve: Number of Compartments Contradictory Feature to Mitigate: Volume/Storage Space
2.
Feature Trying to Improve: Time Required for Making Ice Contradictory Feature to Mitigate: Power Consumption
3.
Feature Trying to Improve: Number of Compartments Contradictory Feature to Mitigate: Time Required for cleaning
4.
Feature Trying to Improve: Automatic Control Features Contradictory Feature to Mitigate: Power Consumption
Exterior Design Alternatives
Pugh Matrix
Pugh Matrix for door/mounting type
Pugh Matrix for automatic controlTitle Automatic Control
Project
Name
Date
Decision Criteria
Item RequirementOverall
ImportanceManual Type
Semi
Automatic
Fully
Automatic
1 Power consumption 29 0 -1
2 Ease of operation 20 +1 +2
3 Keeping food fresh for a long time 22 +1 +2
4 No presence of odor 15 +1 +1
5 Cost of manufacturing 10 0 -1
6 Warranty 4 0 +1
100
Counts
Count of Pluses 3 4 0
Count of Minuses 0 2 0
Count of Same (0) 3 0 0
Pluses - Minuses 3 2 0
Sums
Sum of Pluses 3 6 0
Sum of Minuses 0 -2 0
Total 3 4 0
Weighted Sums
Weighted Sum of Pluses 57 103 0
Weighted Sum of Minuses 0 -39 0
Total 57 64 0
D
a
t
u
m
Add Row
Add Col
Make Datum
Delete
Final Design Concept
• Energy Star Certified- 15% lesser power consumption
• HCFC-22 & HFC-134a-12%
• LCD display
• Integrated Drawer type shelves
• LED lighting
• Ice and water dispensing
• Temperature controlled zones
• Adjustable horizontal and vertical dividers
• Electronic adjustable temperature control
• 7 years life period
• Cost- $1450
Aniruddha Srinath Ketan Bapat Pulkit Agrwal Syed Rehan
Thank You!
Questions??