9780132225519

This book integrates key tools and processes into a comprehensive program for developing more robust and reliable technology-based products. Drawing on their extensive product development expertise, the authors present a complete process for ensuring product performance throughout the entire lifecycle, from understanding customersrs" needs through manufacturing and post launch support. The authors begin by presenting broad insights and high-level strategies for improving technology product quality. Next, they demonstrate how to implement robustness and reliability strategies that complement existing governance and decision processes. A section on tools and methods shows how to institutionalize best practices and apply them consistently. Finally, they tie strategies, decisions, and methods together through a case study project. Product developers will learn how to Understand critical drivers of value in technology products, including reliability and durability Implement a process model and roadmap for improving reliability and robustness Maximize robustness early in development, leading to shorter cycle times in later phases Improve the stability of product performance under stress conditions Assess both organizational and process capabilities for delivering robust and reliable products Understand and manage customer-driven requirements Use tools including descriptive and inferential statistics and DOE-based empirical models Managers will understand expectations for Design concepts supported by rigorous analyses of alternatives Products and processes delivering higher value to customers Products with higher reliability and longer useful lives Product processes with lowers costs and higher capabilities Development projects having shorter, more predictable cycle times Readers are introduced to many thought leaders whose writings can be sources of further learning. This book will be a valuable resource for everyone responsible for delivering reliable, profitable technology products, including general managers, program managers, engineers, scientists, and reliability and quality professionals.

John P. King has made contributions as an engineer, program manager, and laboratory head during a long career in product development and commercialization. His responsibilities have ranged from upstream R&D projects through commercialization and product launch. At Westinghouse, Xerox, Kodak, and Heidelberg Druckmaschinen, John worked as an engineer and manager in developing a wide range of products, including turbo machinery, office products, and medical imaging systems.

As a consultant, mentor, and trainer, John has helped clients worldwide improve both business processes and products. He has worked with project teams for both large and small companies and has written and delivered training programs to clients, followed by project mentoring to ensure the successful completion of their objectives.

John is a member of the American Society of Mechanical Engineers, the American Society for Quality, the American Statistical Association, and the Society of Reliability Engineers. He holds a BME from Rensselaer Polytechnic Institute, an MS in Engineering Mechanics from the University of Pennsylvania, and an MBA from Northeastern University.

Bill S. Jewett is a consultant to businesses engaged in the development of new technologies and multidisciplined products. With insights into important paradigms and advancements in practices, he assists improvement teams in upgrading their engineering and management processes, project management strategies, cross-functional teamwork, and governance of their development projects.

For many years Bill worked for Eastman Kodak Company and Heidelberg Druckmaschinen with much of his focus on the development of high-volume electrophotographic copiers and printers. Among his division-level responsibilities were the management of product development projects and of competency centers for mechanical and systems engineering. At the corporate level he was one of the authors of the processes for advanced product planning, technology development, product commercialization, and their related governance. For over a decade he taught the processes and coached teams in their adaptation and implementation. As the process steward, he evolved the process models to incorporate lessons learned from internal practice and external benchmarking.

Bill participates frequently in the conferences of PDMA, Management Roundtable, and INCOSE. He holds a BSME from Swarthmore College and an MBA from the University of Rochester.

The home page for Mr. Jewett and Mr. King is www.jewettking.com.

Preface xxi

Acknowledgments xxix

About the Authors xxxi

Section I: Critical Drivers of Value

Chapter 1: Time, Money, and Risks 3

Quality, Costs, and Schedules 4

Management of Process Improvements 7

Soft Causes of Poor Reliability and Durability 12

Key Points 20

Discussion Questions 20

Chapter 2: Reliability, Durability, and Robustness 21

Reliability as an Element of Value to Customers 22

Essential Elements of Reliability 23

The Taxonomy of a Failure 26

Reliability Metrics 29

The Anatomy of Quality Loss 33

The Reduction of Performance Variations 39

Key Points 44

Discussion Questions 44

Chapter 3: Strategies for Reliability Development 45

Are Better Strategies Important? 45

Strategies for Ongoing Processes 48

Strategies Specific to Product Development 51

Capabilities of the Organization 57

Key Points 63

Discussion Questions 63

Section II: Framework for Reliability Development

Chapter 4: A Process Model for Product Development 67

What Is a Product Development Process? 67

Integration of Key Development Principles 71

A Process Model for Product Development 76

Advanced Product-Planning Process 77

Technology Development Process 79

Product Development Process 81

Older versus Better Methods 98

Key Points 100

Discussion Questions 100

Chapter 5: Road Map for Reliability Development 103

Build a Compelling Case for Your Reliability Project 103

Linking Activities to the Product Development Phases 104

Key Initiatives of a Reliability Development Project 104

The Role of Testing 116

Key Points 119

Discussion Questions 119

Chapter 6: Effective Decisions 121

Qualities of a Good Decision-Making Process 122

Types of Project Reviews 132

Key Points 144

Discussion Questions 145

Chapter 7: Robustness Development for Product Designs 147

Technology and Product Development 147

Functional Diagram 150

Stressful Conditions 151

Parallel Development of Products and Processes 155

Robustness Development 158

Examples of Robustness Development 162

Robust Design 165

Robustness Development Fixtures 167

Key Points 168

Discussion Questions 169

Chapter 8: Reliability Growth and Testing 171

Product Testing 172

Reliability Growth Testing 174

Drivers of Reliability Growth Rate 181

Accelerated Tests 183

Understanding Stress versus Strength 185

Tools and Systems That Support Testing 190

Overview of Various Types of Tests 196

Key Points 197

Discussion Questions 197

Section III: Tools and Methods Supporting Reliability Development

Chapter 9: Understanding and Managing Customer-Driven Requirements 201

Objectives for Product Development 202

Types of Requirements 203

How Requirements Affect Project Success 206

How Requirements Flow Down 213

VOC Activities Vary Throughout the Development Process 214

The Major Steps in Requirements Gathering 215

Processing and Analyzing Interview Data 221

Key Elements of Requirements Management 227

How Can Your Requirements Efforts Fail? 228

Key Points 229

Discussion Questions 230

Additional Reading 230

Additional Authors Worth Following 230

Chapter 10: Quality Function Deployment 231

What Is Quality Function Deployment? 231

Expected Benefits of QFD 233

The Structure of QFD 234

Sequence of Matrices 244

The QFD Team 245

Suggestions to Improve the Facilitation of QFD 246

Key Points 247

Discussion Questions 248

Amazon no longer offers textbook rentals. We do!

Robustness Development and Reliability Growth : Value Adding Strategies for New Products and Processes

Robustness Development and Reliability Growth : Value Adding Strategies for New Products and Processes

0132225514

Summary

Author Biography

Table of Contents

Supplemental Materials

Write a Review