Preface xiii

1 Introduction to Quality by Design 1

1.1 What Is Quality? 1

1.2 Why Quality by Design? 5

1.3 How to Design for Quality 5

1.4 New Product Development and QFD 6

1.4.1 Reflections on the Development of QFD 8

1.4.2 Reflections on the Evolution of NPD Philosophy 10

1.5 Technology Development and Functionality Design 12

1.6 Outline of This Book 13

PART I Optimizing Design for Function 15

2 Quality Function Deployment 17

2.1 Historical Development and Definition of QFD 17

2.2 The Nature of QFD 19

2.3 Benefits of QFD 20

2.4 Two Dominant Approaches to QFD 21

2.4.1 Akao’s Matrix of Matrices Model 21

2.4.2 The Four-Matrix Model 25

2.5 Shortcomings of QFD 28

2.6 Review Comments on QFD 29

2.6.1 Comments on QFD’s Development Trends and Evolutions 29

2.6.2 Comments on QFD’s Shortcomings 37

2.6.3 Comments on QFD’s Applications 42

2.7 Concluding Remarks 44

3 Expanded System of QFD 45

3.1 Overview of EQFD System and Its Implementation Process 45

3.2 Thirty-Six Steps of the EQFD Implementation Process 51

I. Business and Product Planning 51

II. Technology Development Planning 54

III. Request for Quotation (RFQ) 57

IV. Prototype Design 65

V. Engineering Verification Test (EVT) 68

VI. Design Verification Test (DVT) 69

VII. Production Verification Test (PVT) 76

VIII. Shop Floor Real-Time Management and Abnormality Management 77

3.3 Reinforcement of EQFD for the Original QFD 78

3.4 EQFD Application 92

3.4.1 Quality Deployment 92

3.4.2 Technology Deployment 92

3.4.3 Cost Deployment 102

3.4.4 Reliability Deployment 102

3.4.5 Shop Floor Management 103

3.4.6 Summary 105

PART II Optimizing Design for Functionality 111

4 R&D Paradigm 113

4.1 R&D Strategy as Prediction and Prevention 113

4.2 Conventional Approach to R&D 115

4.3 R&D Paradigm Shift 120

5 Functionality Evaluation 127

5.1 Energy Transformation and Technology Development 127

5.2 Evaluation of Technology 131

5.3 Signal-to-Noise Ratio 132

5.3.1 Dynamic SN Ratio 133

5.3.2 Static SN Ratio 137

5.4 Comparative Assessment of Functionality 141

5.4.1 Conventional Evaluation Indicators 141

5.4.2 Using the SN Ratio 146

5.5 Examples 149

5.5.1 Two Measurement Systems 149

5.5.2 Two Designs 153

6 Functionality Design 157

6.1 R&D and Robust Engineering 157

6.2 Parameter Design for Robustness 159

6.2.1 Key Concepts 159

6.2.2 Key Tools 163

6.2.3 Process Steps 165

6.3 Common Problems of RE Application in Practice 172

6.4 Robust Technology Development 180

6.5 Case Studies 193

6.5.1 Optimization of a Current–Voltage Conversion Circuit 193

6.5.2 Robust Engineering of a Voltage Adjustment Component 212

6.5.3 Accuracy Engineering of a Measurement System 234

6.5.4 Stability Engineering of a Cutting Machine 251

6.5.5 Summary 269

7 Managing for Paradigm Shift 283

7.1 Winning Quality-Based Technology Leadership 283

7.2 Key Success Factors 284

7.2.1 Technical Aspect 286

7.2.2 Managerial Aspect 287

7.3 Benefit to the Organization 290

7.4 Slogan or Strategy? 290

PART III Integration Strategy 293

8 Structure for Design Activity Integration 295

8.1 Universal Roadmap and Nine Tools for Design Engineering 295

8.2 Integration of QFD and Other Breakthrough Strategies 303

8.2.1 Simplified EQFD Model and Its Integration with DFX and DFSS 304

8.2.2 BOS-QFD 308

8.3 Integrated Process for Implementing QFD and RE 312

8.4 Customer-Focused, Rationalized and Effi cient R&D 316

Appendix A Recommended Orthogonal Arrays for R&D 321

Appendix B General Orthogonal Arrays 330

References 349

Index 357

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