Designing Products

and Processes
with a Future

What does it take?

Involve the customer

Meet

with the customer

Listen

to customer

Educate

the customer

Incorporate quality
function deployment
(QFD)

Design for robustness

2

What is a customer?

The person who buys the product?

The federal regulator?
The consumer reporter?
The marketing and sales department?
Engineering?
Manufacturing?
Suppliers?
3

How do you hear the customer?

Features

Needs
Wants
Satisfaction
Perception

Quality
ABOUT

Value
Importance
Competitors
Detractors
4

Product Design
What the Customer
wanted

What Marketing describ

What Engineering designed

Actually Manufactured

What is Design?
A Decision Making Process
Flexibility

Idea generation
Assessment of firms ability
Customer Requirements
Functional Specification
Product Specifications
Concept Generation
Concept Selection
Engineering Design
Engineering Evaluation
Prototype and Testing

Manufacturing

to carry out

Design

Cost
6

Few Successes
Number
2000
1500
1000

Ideas
1750 Market
requirement

1000

Design review,
Testing, Introduction

Functional
specifications

500

500
0

Product
specification
100 25

Development Stage
7

One
success!

QUALITY FUNCTION
Quality Function Deployment
DEPLOYMENT
Uses

the voice of the customer to build a

design tool:

House of quality

QFD: An approach that integrates the voice of the

customer into the product and service
development process.
8

Quality Function Deployment

Identify

customer wants
Identify how the good/service will satisfy
customer wants
Relate customer wants to product hows
Identify relationships between the firms
hows
Develop importance ratings
Evaluate competing products

House Of
Quality
Importance

Product
characteristics

Customer
requirements

Relationship
matrix

Idea Generation Stage

Provides basis for entry into market
Sources of ideas

Market

need (60-80%); engineering &

operations (20%); technology; competitors;
inventions; employees

Follows from marketing strategy

Identifies,

defines, & selects best market

opportunities
11

Customer Requirements Stage

Identifies & positions key product benefits

Stated in core benefits proposition (CBP)
Example: Long lasting with more power
(Sears Die Hard Battery)

Identifies detailed list of

product attributes desired
by customer
Focus groups or
1-on-1 interviews

House of Quality
Product
Characteristics

Customer
Requirements
12

Functional Specification Stage

Defines product in terms of how the

product would meet desired attributes
Identifies products engineering
characteristics
Example:

printer noise (dB)

Prioritizes engineering characteristics

May rate product compared
to competitors

House of Quality
Product
Characteristics

Customer
Customer
Requirements
Requirements

13

Product Specification Stage

Determines how product will be made

Gives products physical specifications
Example: Dimensions, material etc.

Defined by engineering
drawing
Done often on computer

House of Quality
Component
Specifications

Computer-Aided

Design (CAD)

Product
Product
Characteristics
Characteristics

14

Quality Function Deployment

Product design process using

cross-functional teams
Marketing,

engineering, manufacturing

Translates customer preferences into

specific product characteristics
Involves creating 4 tabular Matrices or
Houses

Breakdown

product design into increasing

levels of detail
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To Build House of Quality

Identify

customer wants
Identify how the good/service will satisfy
customer wants.
Relate the customers wants to the
products hows.
Develop importance ratings
Evaluate competing ideas and concepts

Ultimately you choose the desig

Not the custom
16

House of Quality Example

Youve been assigned
temporarily to a QFD
team. The goal of the
team is to develop a
new camera design.
Build a House of
Quality.

1984-1994 T/Maker Co.

17

House of Quality Example

What the customer desires
(wall)

Customer Customer
Requirements Importance

Light weight
Easy to use
Reliable
Target Values

18

House of Quality Example

Average customer
importance rating
Customer
Requirements

Light weight
Easy to use
Reliable

Customer
Importance

3
2
1

Target Values

19

House of Quality Example

Choose engineering
characteristics to satisfy the
customer requirements

Customer
Requirements

Light weight
Easy to use
Reliable

Customer
Importance

Aluminum
Parts

Steel
Parts

Auto
Focus

3
2
1

Target Values

20

Auto
Exposure

House of Quality Example

Relationship between
customer attributes &
engineering characteristics
(rooms)

Customer
Requirements

Light weight
Easy to use
Reliable
Target Values

Customer
Importance

3
2
1

Aluminum
Parts

Steel
Parts

4
19

8
14

Auto
Focus
8
5
21

21

Auto
Exposure

7
3
17

QFD Cascades

22

Sample House of Quality

Adaptation of Piano
Pedals for an Adult

Todd Krzycki

23

Project Description

The Client has Multiple Sclerosis (MS)

which has taken her ability to use her right
leg and more specifically for this project
her right foot. We will design a pedal
adaptation to utilize the Una Corda and
Damper pedals with her left foot with out
making her strain to reach the right pedal.

Todd Krzycki

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Project Objectives
Allow the client to use the Damper pedal
with minimal effort.
Make a lightweight and small adaptive
device to make the right pedal accessible.
Design a device that can be transported
easily from home to school and back.
Avoid any sounds that could detract from
the piano.

Todd Krzycki

25

Apparatus Usage
The apparatus is going to
be used by the left foot of
the client.
Using hands or arms to
activate the pedals is not
feasible because that would
restrict the clients playing
ability.
Using your head or chin to
activate the pedals is an
option but it would make
the apparatus large and
hard to transport.
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Electric Apparatus

Jeff Adams

27

Electric Apparatus
Pros

Cons

Easy to push the pedals

down. The electric
components will do the work
that would have been
required by the client.

Electric components are

costly making the over all
cost of the project high.

Compact. Electric
components are small and
can be made to fit in a small
area.
Apparatus would fit
smoothly between and
around the piano pedals.
Jeff Adams

Safety concerns with

electricity in the apparatus,
as well as chemical concerns
if batteries are used.
Harder to move electric
components around to make
it adaptable to multiple
pianos.

28

Mechanical Apparatus

Jeff Adams

29

Mechanical Apparatus

Jeff Adams

30

Mechanical Apparatus

Jeff Adams

31

Mechanical Apparatus

Jeff Adams

32

Mechanical Apparatus
Pros

Cons

The components that go into a

mechanical system are cheap
since the machining cost are
donated by UT.

A mechanical system will not

allow play of the Damper as well
as the Una Corda pedal with our
clients limitations.

Reliable. You do not have to

worry about a battery dying or
have to find plug to power the
apparatus.

It would have to be larger to

allow for all the transfers of
motion in the system.

There is more feeling in the

operations so it is easier to play
the damper pedal correctly.
Light weight since light weight
materials can be used and
heavy batteries are not needed.
Jeff Adams

The forces used to depress the

pedals would have to be solely
supplied by the client. This may
become a concern if the clients
condition worsens and they lose
more strength in their left foot.

33

Electric/Mechanical Apparatus

34

Electric/Mechanical Apparatus

35

Electric/Mechanical Apparatus

36

Electric/Mechanical Apparatus
Pros

Cons

The Una Corda can be held down

electrically allowing the client use of
their left foot to use the damper pedal.

Electric components are costly

making the cost of the over all
project higher.

Having some electric components

makes it easier to use the fixture in a
range of pianos.

Safety concerns with

electricity in the apparatus, as
well as chemical concerns if
batteries are used.

By having one electric component

instead of two will use less power
making the user less reliant on large
batteries.

Harder to move electric

components around to make it
adaptable to multiple pianos.

Having the damper pedal controlled

by mechanical means allows for more
precise playing of the piano.

Electrical components could

cause noise that would distract
from the sound of the piano.

If no power supply is available the

majority of the functionality of the
apparatus would still be intact.

Relying on electricity for part

of the design is a concern of
the client.
37

House of Quality
Importance

Electrical

Mechanical

Electrical/ Mech.

Light Weight

Size

Universal design

Damper is primary pedal

10

Tactile Response

10

10

Cost

Noise

334

420

442

Safety

38

House of Quality
Importance

Solenoids

Motors

Hydraulics/Pneumatics

Light Weight

Size

Universal design

Damper is primary pedal

10

Tactile Response

Cost

Noise

471

351

296

Safety

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ROBUST DESIGN
Design that results in products
or services that can function
over a broad range of conditions

40

What does Robust Design

mean?

Plan for variability

Assess your capabilities
Design for manufacturing
Reduce costs
Practice!

41

Good Luck
with your designs!

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