Presentation Transcript

1. Design For Craftsmanship

   MPD575 DFX Jonathan Weaver
2. Development History Originally developed by Cohort 1 students: Dave Chronowski, Mark Halseth, Andrew Kernahan, & Roger Maynard (Fall 2000) Revised by Cohort 1 students: Robin Schulz, Beth Robinson (Fall 2000) Underhood examples provided by Lester Weitman added prior to presentation to Cohort 2 (Fall 2001) Revised by Cohort 2 students: Phil Fabien, Ilze Liepa, Joel Simmermon (Fall 2001) MPD575
3. Development History (Cont.) Examples from Cohort 2 assignments added Fall 2001 Examples provided by Robert Ognjanovski added Fall 2002 Later revised by Michael Vinarcik and Joe Torres, Raghavan Setlur, Mac Lunn MPD575
4. Development History Latest updates by many of the following students in winter of 2014: M. Freeman, H. Gasahl, R. Glaser, A. Kammerzell, J. Lambrecht, D. Mincock, J. Murphy, M. Rockwell, P. Roncier, J. Salinas, G. Scalcucci, D. Slater MPD575 Weaver
5. Objectives Define Craftsmanship In Engineering Terms And Heuristics Develop Key Methods And Structure For Evaluating Craftsmanship Of Consumer Products MPD575
6. Contents What Is Craftsmanship? Influences On Craftsmanship Motivation Design For Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
7. Contents What is Craftsmanship? Influences on Craftsmanship Motivation Design for Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
8. What is Craftsmanship? How well executed a given design is in the eyes of the customer. Synonymous with extreme attention to detail, done right the first time, pride in workmanship, and requiring a certain level of expertise and dedication to achieve. In manufacturing, craftsmanshipdirectly results from close communication between design, production, and skilled labor delivering quality product with pride. MPD575
9. What is Craftsmanship? The 'extra' effort expended that allows a final product to surpass the normal limits of utility and functionality, entering the dimension of art and beauty. The ability of skilled workers to put their final touch on the product based on their years of experience and creative artistic skills. Therefore, Design for Craftsmanship, DFC, is the ability of the product designer to allow for such creativity! MPD575
10. What is Craftsmanship? …harmony of the overall interior theme The art and execution of quality. It captures the customer’s perception of quality design and workmanship through sight, sound, smell, and tactile senses The blending of engineering, system architecting, and art to create a product that also has aesthetic appeal MPD575
11. Craftsmanship Is... a perception of quality materials weight/heft/solidity/sturdiness texture alignment tactility appearance compatibility with environment a perception that value is enhanced MPD575
12. Craftsmanship Is... What is a Perception? the electronic touchscreen could be an example of growth area, for transitions, speed, intrusion/asking approval, smooth response and touch response a result of perceiving: observation a mental image: concept awareness of the elements of environment through physical sensation <color perception> physical sensation interpreted in the light of experience Evaluated by the senses - Sight - Sound - Feel/touch - Smell - Taste - Emotion
13. Craftsmanship Is... Intangible (It Is Very Hard To Develop An Objective Metric) Attention To Detail Highly Associated With Brand Interpreted By The Customer The Result Of Specific Efforts MPD575
14. Craftsmanship Impacts… Things Gone Wrong Things Gone Right J. D. Power (or others’) Ratings/Surveys Customer Satisfaction Customer Loyalty Customer Perception of Quality MPD575
15. Craftsmanship Is Not... Measurable Quality R/1000, CPU Robustness Functionality Easily Quantifiable or Measurable MPD575
16. Craftsmanship Is Often Free It Costs Just As Much To Make It Ugly And Slapdash! Craftsmanship Requires More Up-front Thought But Can Be Cheaper In The Long Run (Well-routed Hoses Easier To Service, Etc.) Craftsmanship Is The Clearest Way To Show A Customer That The Entire Organization (From Design To Engineering And Manufacturing) Cares About Details. MPD575
17. Craftsmanship Qualification Scale Objective Subjective less quantifiable more Measured via behavioral science Measured via behavioral science Measured via behavioral science Measured via behavioral science Measured via behavioral science Measured via behavioral science Physical measureable Physical measureable Physical measureable Physical measureable Physical measureable Measured via behavioral science Measured via behavioral science Measured via behavioral science Measured via behavioral science Manufacturing quality Manufacturing quality Manufacturing quality
18. Examples Each Class Member Should Share An Example Of Good Or Bad Craftsmanship MPD575
19. How Do You Make Craftsmanship Happen? Engineers And Automotive Designers Work Together To Interpret The Customers’ Needs, Desires, And Expectations And Then Make Them Happen In The Physical World Two Sides To The Equation: Engineering Design Artistic Design MPD575
20. Contents What is Craftsmanship? Influences on Craftsmanship Motivation Design for Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
21. Influences on Craftsmanship Engineering Design – The Engineering Side Of Craftsmanship, The Part That Can Be Controlled Cost Design For Assembly Design For Manufacture Robustness Tools Assembly Influences MPD575
22. Cost Craftsmanship May Have A Cost Associated With It Difference Between A Focus And A Town Car Or A Cavalier And Cadillac Any Vehicle Pair With The Same Functionality, But Different Levels Of Craftsmanship MPD575
23. Design For Assembly Craftsmanship Overlaps DFA In The Sense That If An Item Has Efficient DFA Then It Should Be Manufactured Such That It Meets The Design Intent. MPD575
24. Design For Manufacture In The Same Sense As DFA, Craftsmanship Overlaps DFM - If An Item Has An Efficient DFM Then It Should Be Manufactured Such That It Meets The Design Intent. MPD575
25. Robustness Tools Design Of Experiments Reduce Variation Find The Key Contributors Control What Can Be Controlled Process Controls Establish What Can Be Controlled Monitor Those Items Take Action When Out Of Control MPD575
26. Robustness Tools Eliminating Excessive Variation In Key Processes Improves Craftsmanship Process Outputs That Impact Fit/Finish/Function Will Drive Customer Perceptions Gaps Between Parts Operating Efforts (Doors, Toolbox Lids, Etc.) MPD575
27. Assembly Influences Operator Dependence This Is The Manufacturing Side Of Craftsmanship Taking The FMEA Approach And Assuming The Process And Design Have Been Optimized To Reduce Operator Dependence, Operators Must Be Trained And Motivated To Assemble The Product As The Designer Intended Ergonomics, Work Practices (Job Rotation, Skill Enhancement, Work Teams) All Play A Major Role MPD575
28. Assembly Influences Jigs And Fixturing This is a subset of DFA And DFM and helps reduce or eliminate operator error Poke-yoke (Pronounced Poh-kah Yoh-kay) Japanese practice that means elimination of error through mandating design of product and/or tooling such that error is impossible. MPD575
29. Artistic Design/Influences Automotive Design Appearance Harmony The artistic side of craftsmanship where beauty is in the eye of the customer and sometimes just the designer The Artist tries to interpret “The intangible needs of the customer” - “The engineer figures out how to bring it to market” MPD575
30. Artistic Influences Appearance This is completely the industrial designers’ world Appearance is highly tied to brand expectations (especially in automotive) Designers try to bring the customer a “sense” of the brand. Try to see if you can guess what the designer had in mind on the next slides... MPD575
31. What Do You Think This Vehicle Looks Like From The Outside? What Is It? MPD575
32. Audi TT Roadster Detroit Auto Show 2000 MPD575
33. What Do You Think This Vehicle Looks Like From The Outside? What Is It? MPD575
34. Volkswagen AACDetroit Auto Show 2000 MPD575
35. Artistic Influences Harmony Do colors, fabrics, and materials match? Do they blend in a pleasing way? Does the design draw you towards the product? Do you want to spend time with it? MPD575
36. Harmony? In What Way? MPD575
37. Contextual Issues The same levels of expectations do not always apply to similar products Engine Compartments (Trucks Vs. Cars) Trucks: larger open areas for accessibility (customers typically like to “see the hardware) Cars: Covers over components with a “High Tech look MPD575
38. Contents What is Craftsmanship? Influences on Craftsmanship Craftsmanship Motivation Design for Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
39. Objective Define What Makes Good Craftsmanship Understand Why Good Craftsmanship Is Important – Four Pleasures Model Add Rigor To The Artistic Side Of Design For Craftsmanship MPD575
40. Contents Characteristics Of Good Craftsmanship Consumer Interpretation Of Good Craftsmanship Impact Of Good Craftsmanship On Business Equation MPD575
41. Contents Characteristics of good craftsmanship Consumer interpretation of good craftsmanship Impact of good craftsmanship on business equation MPD575
42. Simple Design MPD575
43. Simple Design MPD575
44. Thunderbird Simple Design Fender contour flows into theheadlight. The bumper to fender parting line has good alignment to the headlight lens and hood front lip. MPD575
45. Cluttered Design - Relationships Operating Characteristics Complex Relationships Door Sail Large Complex Moldings Door Trim To IP Relationship No Clear Relationships Seams Airbag Cover Door Numerous Added Parts Confusing Operation MPD575
46. Cluttered Design - Relationships See - Through Visible Wires MPD575
47. Cluster Bezel Cluttered Design Register Bezel PAB Cover Number Of Parts Cut Lines See-Through Relationships Symmetry Knee Bolster ICP Bezel IP Substrate Glovebox Door MPD575
48. Surface Finish Choices Grain/Texture Dependant On Manufacturing Process, Material And Tool Maintenance Gloss Level Dependant On Material, Lighting Conditions, Grain/Texture And Manufacturing Process Color Dependant On Paint Source, Grain/Texture/Lighting Conditions And Manufacturing Process MPD575
49. Material Choices Metal Plastic Wood Fabric Others MPD575
50. Material Choices Some Materials Have A Desirable Cachet That Enhances Perceived Craftsmanship (Hardwood Vs. Flakeboard Floors) MPD575
51. Material Choices PVC/ABS TPO PVC Different Materials Can Be Perceived As A Mismatch In Color And Texture ABS MPD575
52. Case Study - Ceiling Fans Examine Two Different Ceiling Fans From A Perspective Of Design For Craftsmanship A B MPD575
53. Ceiling Fan - A Gap Between Blade And Blade Holder Assembly Consistent Margins Parallel/Concentric With Other Features Textured Glass Bulb Cover For Improved Light Dispersion And Hidden Imperfections MPD575
54. Ceiling Fan - A Gap Between Blade And Blade Holder Assembly MPD575
55. Ceiling Fan - A Single Visible Screw To Secure Ceiling Bezel Clean, Simple Surface Lines For Ceiling Bezel Tight Margins Between Down-rod And Ceiling Bezel MPD575
56. Ceiling Fan - B Large Fan Housing Distorts Proportions Of Fan Large Blade Brackets Bearing Little Relationship To Other Elements Of The Design Reflective Finish On Lamp Cover Enhances Blemishes And Is Not Fully Integrated MPD575
57. Ceiling Fan - B Large Black Down-rod Holder Protrudes From Ceiling Bezel Two Attachment Screws Visible For Ceiling Bezel MPD575
58. Ceiling Fan - B Multiple Blade Brackets Increase Number Of Interfaces Between Parts And Are Inconsistent Gaps Between Lamp Cover And Fan Blade Brackets Are Highly Visible And Detract From Overall Design MPD575
59. Ceiling Fans - Conclusion Subjective Analysis Suggests That Ceiling Fan A Represents Better Design For Craftsmanship. A B MPD575
60. Simplify, Simplify, Simplify Reduced Number Of Parts Lower Assembly Costs Fewer Margins To Control Reduced Tooling Costs Eliminate Bezels Fewer Margins To Control Reduced Tooling Costs MPD575
61. Simplify, Simplify, Simplify Common Materials Consistent Gloss Levels Consistent Color Consistent Graining MPD575
62. Simplify, Simplify, Simplify Simple Shapes Reduced Tooling Costs Easier Margin Control Coherent Design (Less Whimsical) Lower Impact Of Environment On Appearance (Shadows, Etc.) MPD575
63. Flushness Due to build variation, manufacturing cannot consistently obtain the perfect theoretical flushness condition However, variation is known Also, which flushness condition looks “worse” is also known Therefore, the vehicle can be built in a nominally underflush / overflush condition so the parts are always assembled in an aesthetically acceptable way

    Margin and Flushness

64. Roof Liftgate

    Margin and Flushness

    Under-flush condition
65. Margin and Flushness Flushness – Cheated Panels Hoods should rigidly remain in their latched position with little to no flutter The latched area is designed to pull away from the latch The areas of the hood bumpers are designed to push into the bumpers The strut forces are also compensated for Hood in Latched Position Hood As Manufactured Bumper Latch
66. Margin and Flushness Flushness – Cheated Panels Latch-able components like hoods, deck lids, liftgates, and side doors have a variety of forces being applied to them. Struts, bumpers, and seals will displace the sheetmetal a given amount In order to compensate for this, the sheet metal panel geometry is manufactured in a “cheated” position Liftgate struts can have several hundred lbs of force on the liftgate while in it’s latched position Strut forces on hatch-back Liftgate sheet metal is formed in the direction opposite the strut forces to achieve as designed flushness targets Roof - Body - Strut - Liftgate
67. Margins Margins are varied to give a particular appearance Margins are not always constant by design

    Margin and Flushness

    Hood – Fender margin may vary to give a particular appearance. Hood Fender Headlamp
68. Contents Characteristics Of Good Craftsmanship Consumer Interpretation Of Good Craftsmanship Impact Of Good Craftsmanship On Business Equation MPD575
69. Craftsmanship Defined Craftsmanship Art And Science Developed Key Design Themes For Improved Craftsmanship In Automotive Field And Consumer Goods Good Craftsmanship Is More Than Just Appearance MPD575
70. What is Craftsmanship? As Interpreted By Consumers: Eyes Of The Customer Extreme Attention To Detail Surpass The Limits Of Normal Utility And Functionality Enter The Dimension Of Art And Beauty The Art And Execution Of Quality Perception Of Quality Design Through Sight, Sound, Smell, And Tactile Senses Harmony MPD575
71. Emotional Satisfaction Interaction With A Product Derives A Sense Of Emotional Satisfaction For The User. Four Pleasures Framework Developed By Anthropologist Lionel Tiger In 1992, And Subsequently Adapted For Use In Design By Patrick Jordan In 1997. Analysis Used By Philips Consumer Electronics In Europe. Jordan, Patrick W And Macdonald, Alistair S; Pleasure And Product Semantics MPD575
72. Emotional Satisfaction Sight Sound Touch Smell Taste INTERPRETATION Psychological Sociological Physiological Ideological MPD575
73. Four Pleasures Physiological – Must Appeal To Physical Senses Sociological – Improve Interaction With Product/Other Consumers Psychological – Must Perform A Needed Function Flawlessly Ideological – Must Be Appropriate MPD575
74. Four Pleasures - Physiological Pleasure Derived From The Physical Senses. Includes Tactile Feedback, Operating Efforts, Feel, Smell, And General Physical Interaction With A Product Examples: Bubble Wrap “Gel” Pen Grip Areas “New Car” Smell Balanced Clutch/Accelerator Pedal/Brake Feel Manual Transmission Shift Feel MPD575
75. Four Pleasures - Sociological Pleasure Derived From The Company Of Others. A Product Which Facilitates Social Interaction Will Be Highly Rated Examples: Internet, E-mail, Chat Rooms Minivan (Flexible Accommodation) Baby Intercom System MPD575
76. Minivan – Flexible Accommodation MPD575
77. Four Pleasures - Psychological Pleasure Gained From The Successful Completion Of A Task Or Goal. A Successful Product Will Help Rather Than Hinder The Achievement Examples: Day Planner Minivan (Fourth Door) HP 49G (Ubercalculator) MPD575
78. Four Pleasures - Ideological Pleasure Derived From The Ownership Of A Product Which Symbolizes The Values And Ideology Of The User, As Described By The Brand Personality. Examples: 5 Star Crash Worthiness Th!Nk Car, Toyota Prius, Honda Insight Firearms Motorcycles MPD575
79. Four Pleasures A Good Design Will Stimulate The Senses And Satisfy The Emotions Of The Consumer Great Appearance Must Be Reinforced With Outstanding Functionality Products Must Be Assessed For Emotional Appeal MPD575
80. Contents Characteristics Of Good Craftsmanship Consumer Interpretation Of Good Craftsmanship Impact Of Good Craftsmanship On Business Equation MPD575
81. Improved Brand Equity Ford vs. Volkswagen (In Europe) Ten Years Ago, VW Was In Midst Of Severe Financial Difficulties Product-Led Recovery With A Focus On Execution VW Generally Considered Craftsmanship Leaders For Mass-produced Vehicles VW Typically Enjoys 10% Higher Margin Over Ford Brand Products One Enabler For VW Has Been Its Ability To Deliver Vehicles With High Craftsmanship With Only Marginal Cost Penalty MPD575
82. ‘Decora’ Light Switches Flush Appearance Improved Feel Reduced Efforts Aesthetically Pleasing Visible Attachments Functionally Identical To Traditional Switches Material Content Comparable Premium Of $5-$7 Per Switch $550 Cost Per House MPD575

83. Craftsmanship for Automotive Seats

84. Craftsmanship as applied to Automotive Seats Definition of craftsmanship from Oxford Dictionary:CRAFTSMANSHIP is the degree of skill in doing a task or of finish in the product made.Craft: skill, ability, ingenuity, art, talent, mastery, expertise, genius, handiwork The first point of contact between any vehicle and the occupant is the seat. A finely crafted seat invites the customer to sit and experience the comfort and fineness of the seat. A poorly crafted seat does not appeal to the customer, and will cause the potential loss of a sale. Craftsmanship is an attribute in the design process which targets the customers perception of vehicle quality (fit, finish and execution) and functions designed for user friendliness. It covers what a customer sees, touches, uses and hears.
85. Elements of craftsmanship and flow process
86. Design Guidelines typically employed Seats designed with the "cleanandneat" look, where the trim cover sew line (style and location) and seat geometry (foam and structure) are well suited for each other; Seat tracks rounded-off with sleek styling that eliminates or hides sharp edges and covers lubricated surfaces so that fingers can't get pinched and clothes can't be soiled. Designed attractively; such that side shields may not even be necessary to cover the seat track mechanism. Operates with low efforts, glides very easily, smooth, quiet and precise. Mounted in a manner to maximize rear occupant foot and leg room when the seat is adjusted to any position.
87. Craftsmanship as applied to Automotive Seats Seat controls that are: Located for easy accessibility at any seat position, with low operating efforts for quick and quiet adjustment. Styled to blend in with the surrounding components with no exposed mechanisms or screws. Shape and size of controls are user friendly with no accessible underside surfaces that are sharp Have structural ribs or have metal
88. Craftsmanship as applied to Automotive Seats Seat Craftsmanship is the customer's overall perception of Seat Quality in: the consistency of theme ... (what the customer sees) the efficiency & cleverness of design ... (what the customer uses) the attention to details with the desire to please ... (what the customer touches) the robustness and reliability of each component ... (what the customer hears). Craftsmanship is hard to measure objectively; but if you see it ... you recognize it. What craftsmanship is NOT;It isn't measured by the number of Seat functions or options,or the complexity of manufacturing process used,or the level of technology employed.
89. Conclusions Design For Craftsmanship Checklist (Simplify, Simplify, Simplify) Overall Design Theme – Lines/Junctions Material Choices Number Of Parts Part Relationships Impact Of Environment On Appearance/Function MPD575
90. Conclusions Emotional Satisfaction More Than Just Appearance Must Satisfy The Senses And Emotions MPD575
91. Conclusions Business Equation Improved craftsmanship can leverage improved business equation Increased revenue Marginal variable/investment cost impact MPD575
92. Contents What Is Craftsmanship? Influences On Craftsmanship Craftsmanship Motivation Design For Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
93. Craftsmanship Heuristics General Craftsmanship Categories For Vehicles Heuristics Specific General Automotive Examples MPD575
94. Vehicle Categories Interior System Instrument Panel Console Assembly Steering Wheel/Column Door Trim Panel Interior Trim Restraints Seats Luggage Compartment MPD575
95. Vehicle Categories Exterior System Front End Greenhouse Rear End Door System Decorative System Underhood Night Time Appearance MPD575
96. Design for Craftsmanship Heuristic MPD575
97. Visible FastenersWrangler MPD575
98. Visible FastenersEscort Covered Fasteners Are Better Than Exposed MPD575
99. Visible FastenersExplorer Sport Trac Grab Handle And Trim Fasteners Are Covered Nicely, But Coat Hook Fastener Left Fully Exposed! MPD575
100. Design for Craftsmanship Heuristic MPD575
101. Minimize Parts In An AreaChevy Blazer MPD575
102. An Unsightly Margin… MPD575
103. A similar Margin Well Presented… MPD575
104. Sight ShieldDodge Ram MPD575
105. Minimize Parts In An AreaAudi A3 MPD575
106. New vs. Old MPD575
107. Overlapping SurfacesAudi A3 MPD575
108. Overlapping SurfacesInstrument Panel Poor Margins On IP Cluster Example With Bezel That Covers The Margin MPD575
109. Design for Craftsmanship Heuristic MPD575
110. Never Show A Sharp EdgeCherokee MPD575
111. Never Show A Sharp EdgeAudi A3 MPD575
112. Never Show A Sharp EdgeDeville MPD575
113. Design For Craftsmanship Heuristic MPD575
114. Avoid Subtle DifferencesExcursion MPD575
115. Avoid Subtle DifferencesLeSabre MPD575
116. Avoid Subtle DifferencesAudi A3 MPD575
117. Design For Craftsmanship Heuristic MPD575
118. Tactile Interfaces Effort Access Expectations MPD575
119. Tactile Effort (Schematic) MPD575
120. Tactile Effort (Schematic) MPD575
121. AccessExcursion MPD575
122. AccessSuburban MPD575
123. AccessZ3 MPD575
124. Tactile ExpectationAccord Pushing Here Will Not Sound The Horn, As Expected! MPD575
125. Design for Craftsmanship Heuristic MPD575
126. Audio InterfacesAudi A3 MPD575
127. Design for Craftsmanship Heuristic MPD575
128. Surface Imperfections Mold Lines Are The Evidence Marks Left By The Joining Of Two Halves Of A Mold Sink Holes Are Left In Injection Molded Plastics Where A Protrusion Exists Beneath The Flat Surface Of A Part Gates Are Blemishes In Injection Molded Parts Where The Feeder Tubes Are Removed MPD575
129. Avoid Mold LinesEscort MPD575
130. Avoid Mold LinesGrand Cherokee MPD575
131. CamouflageToyota Sienna vs Lexus RX 300 MPD575
132. Design for Craftsmanship Heuristic MPD575
133. Product DependenceCavalier MPD575
134. Product DependenceMercedes S500 MPD575
135. Product DependenceSuburban MPD575
136. Mustang: Wrong Direction over Time? Cost And Craftsmanship May Correlate The Following Is A Comparison Of Some Exterior Mustang Craftsmanship Issues (1994-2002) MPD575
137. 1994 vs 2002 Mustang Brake Light Is Incorporated Into The Spoiler Providing A “Clean” Appearance. Taillight Modules Color Matched To Body. Common Theme Of Smooth Horizontal Lines. Brake Light Is 3X Larger And Incorporated Into Trunk. Tail Light Modules, Fascia Perforations And Cut Lines Do Not Appear To Have A Common Stylistic Theme. Redesigned Quarter Panel And Unpainted Mirrors Emphasize Gaps And Incongruent Fit. Door, A-pillar, Quarter Panel Intersection Is Smooth Due To Painted Mirrors And Panel Design. Functional Air Vents For Improved Aerodynamics As Well As Styling. Non-functional Painted Plastic Appliqués Are Subject To Quality And Durability Concerns. MPD575
138. B A The “Cut Lines” Within Each Stamping Do Not Match Up With The Interfaces Between Body Panels. In Example A The Relationship Of Quarter Panel To Fascia Appears To Be Incongruent. In Example B, Hard Lines Caused By The Accentuated Fender Lip Break The Cut Line That Travels The Length Of The Body. In The 2002 Model, The Door Handle Is An Extremity To The Body Side. The 1994 Model Is Recessed And De-emphasized As Captured On The Previous Slide. MPD575
139. A Final Heuristic: Hide the Ugly! MPD575
140. Contents What Is Craftsmanship? Influences On Craftsmanship Craftsmanship Motivation Design For Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
141. Examples Of Average Craftsmanship ( ) ( ) Positive Aspects Color Coordination Of Service Bottles Caps (Fiesta) Fiesta NegativeAspects Poor Coordination Of Hoses And Wirings Exposed Hardware And Mechanisms Busy Appearance MPD575 Honda CRV
142. Examples Of Average Craftsmanship ( ) ( ) Positive Aspects Clean Appearance Of Major Parts Covers (Air Filter, Battery, Etc.) Fiat Palio Negative Aspects Wires And Hoses Not Coordinated Visible Part Number Labels MPD575 Ka
143. Examples Of Good Craftsmanship ( ) ( ) Positive Aspects Covered Brand Badge With Good Appearance No Visible Supplier Labels Clean Appearance Of Covers VW Gol Negative Aspects Appearance Of Colored Wires Hood Lock Mechanism Exposed MPD575 Peugeot 206
144. Examples Of Excellent Craftsmanship ( ) Positive Aspects Clean Appearance Covered Hoses And Wirings Coordinated Engine Type And Brand Highlighted Location Of Oil Dipstick Bottles And Caps On Outer Sides Audi A6 MPD575 VW Golf
145. Examples of Bad Craftsmanship ( ) Peugeot 206 Negative Aspects Washer bottle cap poorly located, hose on reach zone and no clearance to fender edge Oil dipstick located close to heat area (exhaust manifold) Screws with different color of background MPD575 Peugeot 206
146. Examples Of Good Craftsmanship ( ) Positive Aspects Fresh Air Hose For PVC Well Executed Fuse Panel; Good Appearance Of Cap With Graphics Embossed, Good Fit Of Wiring Harnesses To Cap Peugeot 206 MPD575 Peugeot 206
147. Examples Of Good Craftsmanship ( ) Positive Aspects Battery; Located Square With The Engine And Other Components Good Appearance Of Cover And And Fit To Other Components Hood Prop Rod; Not On Reach Zone For Servicing Engine Compartment Peugeot 206 MPD575 Peugeot 206
148. Examples Of Bad Craftsmanship ( ) Fiesta Negative Aspects Part Label Exposed And Poorly Attached Washer Bottle Cap; No Clearance To Fender Edge, Possible Hand Injuries MPD575 Fiesta
149. Examples Of Good Craftsmanship ( ) Positive Aspects Hood Prop Rod; Covered, Color Coordinated And No Paint Chips At High Time In Service Due To Plastic Attachment Hood Secondary Release Touch And Feel Area; Covered (But With Exposed Mechanisms) Fiesta MPD575 Fiesta
150. Examples Of Bad Craftsmanship ( ) Fiat Palio Negative Aspects Big And Not Centered Latch Different Color Highlights Part On A Dark Background Fiat Palio MPD575
151. Contents What is Craftsmanship? Influences on Craftsmanship Craftsmanship Motivation Design for Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
152. Assessment Process How Do You Measure Craftsmanship? Determine Attributes Of Product To Measure Use A Weighted Average Assessment Scale Weighting Of Attributes: 0-5 (0 – Unimportant, 5 – Important) Evaluate Product Against Attributes: Scoring Of Product: 0-6 (0 – Worst, 3 – Industry Average, 6 – Best) MPD575
153. Assessment Process Is It Best Performed By One, The Few Or The Many? Because Of The Subjectivity Involved, It Is Best Performed By As Few People As Possible They Should Remain Autonomous To Minimize Influences They Perform The Analysis Of The Entire Industry Under Review For Consistency They Are “Trained Eyes” That Know What To Look For, Know What The Customer Expects, And Know How Much Weight To Apply To It MPD575
154. Assessment Process Let’s Try An Example Underhood Of A Vehicle MPD575
155. Perceptions Count Underhood appearance is good or bad, depends on your opinion. VW and BMW can have great underhood appearance, but very few see or care from experience. So is poor underhood appearance worth effort and (yes the BMW level costs money) worth it? Plastic covers are compromise to hide things. A functional snow pack shield or NVH dampening cover is sometimes justification for “craftsmanship”. The GTDI twin turbo engine is as much an NVH cover as an appearance cover for a great performance engine! MPD575
156. Assessment Process The Coordination Of Hoses And Wiring Routings Is The Attribute Of Interest Subjectively, This Attribute Is Assigned A Weighting Factor Of 5 Each Car Is Rated From 1 (Poor) To 6 (Superb) MPD575
157. Assessment Process What Is The Score? Few Hoses Visible Layout Seems Somewhat Well Thought Out Coolant Recovery Hose Seems To Just Lay Across Everything Else Score: 3 Car #1 MPD575
158. Assessment Process What Is The Score? “Bunch Of Snakes” Look Hoses Not Coordinated Hoses Just Laying On Top Of Other Parts Score: 2 Car #2 MPD575
159. Assessment Process What Is The Score? Few Hoses Visible Layout Seems Somewhat Well Thought Out Red Wires In Middle Highly Detract From Overall Look Score: 4 Car #3 MPD575
160. Assessment Process What Is The Score? “Bunch Of Snakes” Look Hose/Wire Routing Not Coordinated Hoses Just Laying On Top Of Other Parts Score: 1 Car #4 MPD575
161. Assessment Process What Is The Score? Few Hoses Visible Layout Seems Somewhat Well Thought Out Hose/Wire Routing Is Neat And Organized And Parallel To Each Other Score: 5 Car #5 MPD575
162. Assessment Process What Is The Score? Very Few To No Hoses/Wires Visible Layout Seems Very Well Thought Out Score: 6 Car #6 MPD575
163. Assessment Process MPD575
164. Assessment Process MPD575
165. Assessment Process Total All Attributes Highest Score Shows The Best Vehicle MPD575
166. Assessment Process Summary Try To Find The Areas Of Craftsmanship That The Customer Values Over The Others And Spend Time And Money In Perfecting These Items These Expenditures Can Be Decreased By Using Carry-over Parts That Are Known To Achieve High Craftsmanship Ratings Do Not Spend Time And Money On Items The Customer Does Not Value Or Cannot See MPD575
167. Fonts Are Large, Clear And Easy To Read Grains Hide Imperfections In Molding Process Poor Alignment Hubs Cover Interface Between Stationary And Moving Parts Mask Covers Edges Of Appliqué Assessment Process High Craftsmanship Value Parts Extra Efforts Are Spent In Perfecting The Surface, Color, And Texture Of An Instrument Cluster, Because It Is Something The Customer Always Sees When Operating The Vehicle MPD575
168. Bezel Provides A Clean, Smooth Edge Allows Tactile Feedback Backlit For Operation In Low Levels Of Light Assessment Process Standard Craftsmanship Parts Efforts Are Spent To Select A Material And Apply A Texture That Allows Operation In The Coldest Of Temps While Not Showing Finger Prints For Security Reasons MPD575
169. Material Flow Swirl And Sink Marks Assessment Process Low Craftsmanship Value Parts This Electronic Module Is Packaged Behind The Trim And Is Not Visible To The Customer. Minimal Efforts Were Applied In Perfecting The Surface, Color Or Texture Of This Housing MPD575
170. Assessment Process Conclusions Spend Additional Resources On Parts And Interfaces That Have High Customer Value Spend Little Resources On Parts And Interfaces That Have Little Customer Value It Is All A Trade-off In The End And The Law Of Diminishing Returns Is In Effect MPD575
171. Contents What is Craftsmanship? Influences on Craftsmanship Craftsmanship Motivation Design for Craftsmanship Heuristics Underhood Craftsmanship Assessment Process MPD575
172. A Final Warning Some Craftsmanship Choices May Impact Other Engineering Trade-offs Underhood Beauty Cover Impacting Air Flow And Heat Management Fountain Pen Material Choice Will Impact Cost And Fabrication Technique (Wood vs. Plastic vs. Metal) MPD575
173. Other DFC Considerations Certain vehicle components, if replaced, could cause collateral damage to adjacent systems that depend on the component in OEM form. Example: Underbody shield with cooling ducts being replaced with a skid plate using no ducts can result in overheating The designer should use caution when selecting fasteners. Joints or components which must not be tampered with need to either A: Eliminate the joint/interface B: Use fasteners which cannot be removed by common tools C: Use one-way fasteners C: Prevent the user from disassembling the system down to the component level (Ex: use press fit on a water pump shaft to prevent replacement with a substandard part)
174. References The American Society of Mechanical Engineers, ASME Y14.5M-1994, 1995 Poka-Yoke information http://www.campbell.berry.edu/faculty/jgrout/textonly.html Jordan, Patrick W and MacDonald, Alistair S; Pleasure and Product Semantics Zero Quality Control: Zero Source Inspection and the Poka-Yoke System, Shingo, Shigeo. 1986 translation, A.P. Dillion, Portland, Oregon: Productivity Press. A good source of information: http://www.campbell.berry.edu/faculty/jgrout/textonly.html A good source of bad information: http://www.baddesigns.com/ MPD575
175. References BV Platforms Craftsmanship Guidelines, Amazon Underhood, M. Longuinho, 7-28-2000. Provided by L. Weitman, Cohort 2 with permission to use here. MPD575

176. Design for Craftsmanship

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