1. MPD 575DESIGN FOR QUALITY Developed By: Sam Abihana Ion Furtuna Adithya Rajagopal

2. INTRODUCTION • Definition of Quality • What is DFQ • How DFQ fits into the Ford PD process • DFQ Process Flow • Example of DFQ Applied to the Seat System

3. DEFINITION OF QUALITY • The Customer defines Quality Our customers want products and services that throughout their lives meet their needs and expectations at a cost that represents value – Ford Quality Policy • Fitness for use (Fitness is defined by the customer) – J.M. Juran • The totality of characteristics of an entity that bear on its ability to satisfy stated and implied needs – ISO 8402 • The loss a product imposes on society after it is shipped – Taguchi • A subjective term for which each person has his or her own definition – American Society for Quality

4. DESIGN FOR QUALITY (DFQ) • Quality is intrinsic to a design and is dependent on: • Choice of system architecture • Robustness of execution during the PD process • Quality is primarily associated with two aspects i.e. functional performance and customer perception • DFQ is the disciplined application of engineering tools and concepts with the goal of achieving robust design development and definition in the PD process • The DFQ process allows the engineer to: identify, plan-for and manage factors that impact system robustness and reliability upfront in the design process

5. DESIGN FOR QUALITY (DFQ) • Common product design tools associated with DFQ, and discussed in this presentation, are: • Boundary Diagrams • Interface Matrix • Parameter Diagram (P-Diagram) • Design Failure Mode and Effects Analysis (DFMEA) • Reliability Checklist (RCL) • Reliability Demonstration Matrix (RDM) • Design Verification Plan (DVP) • The engineering concepts associated with the tools identified above are based on proven methods which can be applied across a variety of industries

6. PHASES IN UNDERBODY DEVELOPMENT UP V0 (VG-T-80) UP V0 (VG-T-80) UP V0 (VG-T-80) UP V0 (VG-T-80) UP V0 (VG-T-80) UP V1 (VG-T-24) UP V1 (VG-T-24) UP V1 (VG-T-24) UP V1 (VG-T-24) UP V1 (VG-T-24) UP V2 (VG-T-04) UP V2 (VG-T-04) UP V2 (VG-T-04) UP V2 (VG-T-04) UP V2 (VG-T-04) VP Dwg. (VG-E-65) VP Dwg. (VG-E-65) VP Dwg. (VG-E-65) VP Dwg. (VG-E-65) VP Dwg. (VG-E-65) UN V0 UN V1 UN V2 M1DJ PHASES IN UPPERBODY DEVELOPMENT UP V0 UP V1 UP V2 FDJ DFQ IN THE FORD PD PROCESS (GPDS) • UN V0/UP V0: Boundary Diagram/Interface Analysis/P-Diagram/DFMEA/RDM/RCL initiated. Quality History review and documentation completed • UN V1/UP V1: Boundary Diagram/Interface Analysis/P-Diagram/DFMEA/RDM/RCL updated • UN V2/UP V2: Disciplines completed, DFMEA updated with recommend actions • M1DJ: Under Body Engineering Freeze/Signoff • FDJ: Upper Body Engineering Freeze/Signoff

7. PRODUCTDESIGN BOUNDARY DIAGRAM INTERFACE MATRIX P-DIAGRAM DFMEA RELIABILITY CHECKLIST ROBUSTNESS DEMONSTRATION MATRIX DVP PROCESS DESIGN PFMEA CONTROL PLAN DFQ PROCESS FLOW

8. BOUNDARY DIAGRAM What? • Defines the scope of the system being studied • Identifies components that are internal to the system • Identifies system-system, system-human and system-environment interfaces (External Components) • Defines the scope of the DFMEA i.e. elements within the boundary • Indicates the nature of all interface relationships • Represents all of the above in a clear graphical manner

9. BOUNDARY DIAGRAM Why? • Provide a disciplined approach to ensuring all system interfaces are considered at design initiation • Understand the nature of interface relationships i.e. • Physically touching (P) • Energy transfer (E) • Information transfer (I) • Material exchange (M) • Communication tool which facilitates team understanding and collaboration

10. BOUNDARY DIAGRAM How? • Identify components within the system as blocks • Establish relationships between the various blocks • Establish relationships between system components and other systems, including customer input • Construct a boundary line around what is best included within the analysis of the system • Boundary diagram analysis should follow system hierarchy down to the desired sub-system, component level

12. Door Trim Panel Floor Pan Wiring Harness (Vehicle) P.2.1+E P.5+E Seat Cushion Asy P.5+E Cushion Pan Asy P.2.2+E Track Asy P.4+E P.2.1+E Recliners Seat Buckle Asy P.4+E P.8+E P.4+E OCCUPANT P.6+E Seat Back Cushion Asy Back Frame Asy Lumbar Asy P.8 P.5+E Head Restraint Assembly SEAT SYSTEM BOUNDARY DIAGRAM P.2.1+E P.5+E P.8+E

13. BOUNDARY DIAGRAM LEGEND

14. INTERFACE MATRIX What? • Provides a supplemental analysis of the boundary diagram • Quantifies the strength of system interactions • Provides input to the Potential Effects of Failure and Severity column of the DFMEA • Robustness linkage to the P-Diagram • Positive interactions may be captured on the P-Diagram as input signals or output functions • Negative interactions may be captured on the P-Diagram as input noise or error states Why? • Cross-check boundary diagram interfaces • Verify positive interactions • Manage negative interactions for robustness

15. INTERFACE MATRIX How? • List all elements within the boundary diagram and all elements that interface across the boundary in the left most column of the Interface Matrix sheet • Fill the 4 quadrants (Q1-Q4) representing the interface relationship (P, E, M, I) between the elements of the Boundary Diagram with a rating from -2 to +2 2 = Necessary for function 1 = Beneficial but not absolutely necessary for function 0 = Does not affect functionality -1 = Causes negative effects but does not affect functionality -2 = Must be prevented to achieve functionality

16. P E I M

17. P-DIAGRAM What? • A graphical tool to identify the operating environment in robustness focused analysis • Provides a structured method to identify: • Intended Inputs (Signals) • Intended Outputs (Ideal Function) • Unintended Inputs (Noise Factors) • Unintended Outputs (Error States) • Design Controllable Factors

18. P-DIAGRAM What? Noise factors are classified as: • Demand related noise which are external to the design • Piece-to-Piece Variation (N1) • Changes Over Time (N2) • Capacity related noises which are internal to the design • Customer Usage (N3) • External Environment (N4) • System Interactions (N5)

19. P-DIAGRAM Why? • Brainstorming tool that supports downstream noise factor management strategies (RCL) and verification methods (RDM/DV) • Links to the Function, Potential Failure Mode and Potential Effect of Failure columns of the DFMEA

20. P-DIAGRAM How? • P-Diagrams should support the scope of the system defined in the Boundary Diagram • Input & Output Signals: Identified in terms of physics as positive interactions in the Interface Matrix • Noise Factors (N1-N5) & Error States: Identified in terms of physics as negative interactions in the Interface Matrix. Brainstorming should be applied to supplement identification of Noise Factors • Error States: Undesired function. Quality History should be used to supplement identification of error states • Control Factors: List of design factors that can be controlled in design i.e. materials, dimensions, location etc.

21. SEAT SYSTEM P-DIAGRAM

22. DFMEA What? • A tool which supports activities that recognize and evaluate potential failure modes of a product and its effects • Identifies actions which could reduce or eliminate the chances of the failure occurring • Documents the analysis process

23. DFMEA Why? • Improve the quality of product evaluation by applying a standardized method • Determine how failure modes will be avoided in design • Allows the engineer to recognize high priority/high impact failure modes and prevent them from occurring • Improve the robustness of the DVP and process control plans

24. P-Diagram Linkage Boundary Diagram Linkage Interface Matrix Linkage DFMEA: ROBUSTNESS LINKAGES

25. DFMEA: HOW?

26. 5 4 7

27. SEAT SYSTEM: DFMEA 2 30 SEAT CUSHION Support 200K jounce cycles (90cpm) of 50th percentile male butt form loaded to 200lbs with seat sag <25mm Seat sag >25mm Poor appearance Customer discomfort Inadequate foam density and ILD D: DV Jounce Testing 5 3

28. ROBUSTNESS CHECKLIST (RCL) What? • Captures noise factors and error states identified in the P-Diagram • Identifies areas that require design based noise factor management strategies • Indicates verification methods which provide the ability to test for the error states associated with the noise factors

29. ROBUSTNESS CHECKLIST (RCL) Why? • Initiate team discussion regarding noise factor management strategy (NFMS) and robust verification • Focus on noise factors which have the highest impact on system robustness • Understand the correlation between the error states and associated noise factors • Assist robust verification by identifying noise factors which are currently not captured by existing DVM’s

30. ROBUSTNESS CHECKLIST (RCL)

31. RCL: HOW? Step 1: Choose ideal functions Step 7: List applicable DVM’s Step 8: Use an X to show error states identified by DVM. Identify High Impact DVM’s Step 2: Choose focused error states Step 3: List associated noise factors Step 4: Define metric and range for each noise factor Step 6: Define NFMS Step 9: Use an X to show noise factors included in the DVM Step 5: Assess strength of correlation between error state and noise factor

32. SEAT SYSTEM: RCL

33. RDM/DVP What? • Planning tool that documents: • Design Verification Methods (DVM) • Level Tested • Acceptance Criteria • Test Timing • RDM is a subset of the DVP that additionally documents: • Failure Mode (Hard or Soft) • DVM for select tests specified by the RCL • Noise Factors being tested • Robustness targets in relation to customer expected function. Targets of R/C (R90/C90) are not acceptable

34. RDM/DVP Why? • Demonstrates that components/systems fulfill reliability requirements identified in the RCL • Provides a forum to review the high impact error states and noise factors that affect the system along with the identified DVM to prove out their system • Structured documentation of verification test plans and timing • Provides single point summary of test plans

35. FROM RCL RDM: HOW?

36. DVP: HOW?