All entries for January 2014
January 24, 2014
Writing about web page http://www.youtube.com/watch?v=6xFI_MjtrbY
I was so touched by the video that was played by Jane in class today on the crash of Germany's ICE 884 train on June 3, 1998 so I decided to watch it again. I believe it was an eye opener to many Engineers and nations across the world. The version of the video I watched showed that some faults were earlier identified on the faulty wheel that led to the crash but they were neglected by the maintenance department which is so bad.
I particularly liked the way the investigators picked each evident one after the other and analysed it until all the causes were identified. I see a root cause analysis being used here. For example, after they saw the first metal that pierced through the floor of train from the wheel that was broken as a result of fatigue caused by load and wear and tear, they kept analysing further to find other causes. the from the gaurd rail that pierced through the
As I was watching I kept thinking and saying "okay that was cause so sad..." but before I knew it, they would find another evident, they did not conclude hastily but kept digging on to come out with a rich analysis and true causes which were a combination of so many factors. This is good case of FRACAS. Failure Reporting and Corrective action system. Where the failure of the wheel was reported after the investigation and corrective measures taken in the production of next batches and I also I am not wrong if I add that some level of fault tree analysis was used here.
This incident also makes it clear the imporatance of DFX, if the wheels were tested to understand what its limits are in terms of life cycle, how much load it can take over a period of time and also considering the speed limit (125miles per hour) of the train i believe a better design would have been made.
I would like to link this to the aerospace sector in Nigeria, We are seriously hoping for a turn around in the maintenance culture. We have recorded lots of plane crashes in the past 10years and near misses. just last december while in Dubai we got a phone call that a plane lost a tire while landing but fortunately no serious casualty was recorded. I want to add that it is not enough to design for reliability. "Maintainability" should always be a factor to support "Reliability" because even we human beings we sometimes need the expertise of our GPs (Doctors) to fix a part of us that needs to be fixed. (smiles).
May the lost souls continue to rest in peace.
January 21, 2014
No product is meant to last a life time, even human beings do die when they grow old. But it is the job of the manufacturers to make sure it last for the period of time it was produced for and serves rightly the purpose for which it was produced for. But in a case where the product begins to fail at midlife or earlier than it should then there is a question whether the design was really good or whether the maintenance is of standard. This and many more are the reasons why Design for X is imporatant
The importance of reliability cannot be overemphasized in the case of military devices and aerospaces, We do not want this machines to fail unexpectedly while in use.
The excercise in class yesterday on the UA232 plance crash did opened my mind to see to see how important it is to not to miss any aspect of the machine that needs to maintained while carrying out the maintenace jobs.
Yesterday I learnt that it is not just enough to get the VOC (voice of the customer) about your product. The VOC must be transfered to attainable objectives. A customer focued approach must be achieved. So that we can satisfy oir custimers. Yes even though we know that satisfiscation can not be perfect but at least we should work harder to reduce the unsatisfaction level. Really because if we want to remain to in business for a llong time we need to strategise how to keep our customers happy most of the time. Because when they are happy, they will come back.
Its easy to use ourselves as example in situtions like this. We will always prefer to go to the salon where the customer service is good for example or buy stuffs from shops where the services are good.
So as managers/future business owners this is something we should look out for.
January 10, 2014
Having reflected on the week's work on PEUSS and the presentations done by my group and other groups I would say that I have learnt quite alot in such a short time about DFSS, DMADV and QFD
Even though my group's topic on DFSS and EFQM, but i also learnt about DFSS in a service company,six sigma vs DFSS, R&M and DFSS. I left the class with some highlights from these presentations given by other teams.
So before then I was wondering how practically DFSS can be used in a service industry, but one the group did illustrate that even though most of the point were six sigma related, I could make the connections which he did also make at the end of the presentation.
Highlights on my group's presentation topic; DFSS concept relevant to business excellence?
Using EFQM: I would say yes DFSS concept is relevant to business excellence because it makes sure that the products, processes and services are produced primarily to satify the customer so that good customer result is achieved. Even though, DFSS might not be able to make the organisation achieve overall success but it can contibute to the strive for excellence. So it is highly relevant.
January 09, 2014
While reading a text on on DFSS in preparation for the presentation on friday, One thing kept stroking me, which is the importance of communication is the application of DFSS. Since it is a concept that uses basically the "Voice of the customer"(the customers's requirements)
It is important to ensure that information is passed on correctly from the sales team (the requirement gathering team) to the design and manufacturing team because if the customer's requirements are misinterpreted, the project team will end up producing what the customer did not request. Which I want to believe will lead to a waste of resource (time, efforts and money).
January 08, 2014
Today's group meeting and brain storming seesion went well and my team mates are great fellows. :)
So here's what I have discovered for myself,
From CBE and PIUSS I learnt that EFQM and Six sigma are both derivatives of Deming's work on statistics and quality management. DFSS is an approach that can be used to achieve business excellence. Using the EFQM model, the EFQM has 9 criterion and the product/services/processes, leadership,customer result, business result are related to the concept of DFSS. DFSS is customer and result(design) focused. Even though EFQM is broader than DFSS which is just applied at the design phase. It is okay to say that DFSS concept is relevant in the strive for business excellence.
January 07, 2014
QFD stands for Quality function Deployment. Just as the name implies, it focuses on deploying quality functions that meets or exceeds the customer's requirements.QFD is provides strong customer focus. It is a very imporatant tool that should be applied early in the product life cycle. The case is diferent in the real world. Producers are more in a hurry to send their products out to market especially when launch dates have been set.
I want to believe it is not a crime to push launch dates forward. Is it not better for the production to be to be delayed and at the end of the day a good and near perfect product is delivered than for it to be rushed out just so it can meet the deadline. Well I understand they want to appear competent to the customers and their competitors but still this should not completely influence their decision to do such.
Today in class most the opinion about why companies do not used QFD was centered around "time consumption"; yes it certainly going to be time consuming to apply QFD in the design phase and equally expensive but I want to believe it is better to spend all the money and efforts on the design of product so that it comes out sound and everybody is happy. It just like planning. We can all agree that the importance of planning cannot be over emphasized.
Let me bring it home a little. It is usually easier to produce a good essay after some planning has been done. From my little tiny bit of personal experience about PMAs. (hahaha)
It is way tougher to start if I didnt put down a plan which most time is in form of a mindmap. This sort of gives me a focus and guide to work with. A good plan begets a good work and vice versa. And I believe this same principles apply to the real world in product design.
For the PMAs the voice of the customer is the PMA question: the requirements of the question.
There is a common saying; if you do not plan, you plan to fail. QFD is could help industries save alot of money by making sure that the customer's requirements are met through the best method of prioritising and maximazing efforts and resources available and at the same time striving to achieving competitive edge.
QFD is very critical for production and manufacturing industries be it services or products and most not be overlooked.
Its drills down to the nitty gritty of things. It even displays a little bit of opportunity cost and scale of preference. Where you can organise the function that is most important ( higher in priority) and would not impede other functions. So it helps create a balance that the human eyes and brain would not have been able to create just imagining.
January 06, 2014
Loved it today in class and I would say quite an interesting way to start the year. Happy new year readers....
It was the first day of PEUSS -product excellence using six sigma and I was thrilled by the idea of DFSS- Design For Six Sigma. DFSS is an improved version of classic six sigma. Classic six sigma is all about improving the already existing processes, products and services while DFSS is proactive; doing it right at the first time. It came about from the limitations of classic six sigma which uses the DMAIC as its methodology and DFSS uses DMADV. DFSS listens to the voice of the customer and prioritises critical to quality issues while making sure that the funictions are key.
So in essence, DFSS is more future and long-term focused because if the products are improved in terms of design there'll be no need to spend money during the process to improve the product.
There is a case where Toyota was said to have called back about 885,000 vehicles in 2013 to fix a problem that could result in a water leak from the air conditioning unit. This definately must have had impact on their
revenue for that year. At this stage what can be done is product improvement. identifying and fixing problems whereas with DFSS the design is critically looked at and verified before production and launching and so it can be said that with DFSS there is no need to worry about the cost of making a design change when the product is already in the market and so financial benefits is long term.
DMAIC- Define, Measure, Analyse, Improve and Control
DMADV- Define, Measure, Analyse, Design and Verfy
From the full meaning of the methodologies, it is clear that one is more interested in improvingwhile the other in designing.