Cover......Page 1
Contents......Page 8
Preface......Page 22
Acknowledgments......Page 30
About the Authors......Page 32
Section I: Critical Drivers of Value......Page 34
CHAPTER 1 Time, Money, and Risks......Page 36
Quality, Costs, and Schedules......Page 37
Management of Process Improvements......Page 40
Soft Causes of Poor Reliability and Durability......Page 45
Discussion Questions......Page 53
CHAPTER 2 Reliability, Durability, and Robustness......Page 54
Reliability as an Element of Value to Customers......Page 55
Essential Elements of Reliability......Page 56
The Taxonomy of a Failure......Page 59
Reliability Metrics......Page 62
The Anatomy of Quality Loss......Page 66
The Reduction of Performance Variations......Page 72
Discussion Questions......Page 77
Are Better Strategies Important?......Page 78
Strategies for Ongoing Processes......Page 81
Strategies Specific to Product Development......Page 84
Capabilities of the Organization......Page 90
Discussion Questions......Page 96
Section II: Framework for Reliability Development......Page 98
What Is a Product Development Process?......Page 100
Integration of Key Development Principles......Page 104
A Process Model for Product Development......Page 109
Advanced Product-Planning Process......Page 110
Technology Development Process......Page 112
Product Development Process......Page 114
Older versus Better Methods......Page 131
Discussion Questions......Page 133
Build a Compelling Case for Your Reliability Project......Page 136
Key Initiatives of a Reliability Development Project......Page 137
The Role of Testing......Page 149
Discussion Questions......Page 152
CHAPTER 6 Effective Decisions......Page 154
Qualities of a Good Decision-Making Process......Page 155
Types of Project Reviews......Page 165
Key Points......Page 177
Discussion Questions......Page 178
Technology and Product Development......Page 180
Functional Diagram......Page 183
Stressful Conditions......Page 184
Parallel Development of Products and Processes......Page 188
Robustness Development......Page 191
Examples of Robustness Development......Page 195
Robust Design......Page 198
Robustness Development Fixtures......Page 200
Key Points......Page 201
Discussion Questions......Page 202
CHAPTER 8 Reliability Growth and Testing......Page 204
Product Testing......Page 205
Reliability Growth Testing......Page 207
Drivers of Reliability Growth Rate......Page 214
Accelerated Tests......Page 216
Understanding Stress versus Strength......Page 218
Tools and Systems That Support Testing......Page 223
Overview of Various Types of Tests......Page 229
Discussion Questions......Page 230
Section III: Tools and Methods Supporting Reliability Development......Page 232
CHAPTER 9 Understanding and Managing Customer-Driven Requirements......Page 234
Objectives for Product Development......Page 235
Types of Requirements......Page 236
How Requirements Affect Project Success......Page 239
How Requirements Flow Down......Page 246
VOC Activities Vary Throughout the Development Process......Page 247
The Major Steps in Requirements Gathering......Page 248
Processing and Analyzing Interview Data......Page 254
Key Elements of Requirements Management......Page 260
How Can Your Requirements Efforts Fail?......Page 261
Key Points......Page 262
Additional Authors Worth Following......Page 263
What Is Quality Function Deployment?......Page 264
Expected Benefits of QFD......Page 266
The Structure of QFD......Page 267
Sequence of Matrices......Page 277
The QFD Team......Page 278
Suggestions to Improve the Facilitation of QFD......Page 279
Key Points......Page 280
Further Reading......Page 281
Decisions in Product Development......Page 282
Concept Generation and Selection......Page 283
Process Guidance......Page 289
Teamwork......Page 292
Discussion Questions......Page 293
CHAPTER 12 Axiomatic Design......Page 294
Axiomatic Design......Page 295
Improvement of Design Concepts......Page 305
System Decomposition......Page 307
A Familiar Example......Page 312
Discussion Questions......Page 315
Project Team Meetings for Risk Reduction......Page 318
Useful Tools Provide Valuable Benefits......Page 319
Risk Analyses......Page 322
Matrix Analyses......Page 327
Flowcharts......Page 329
Tree Analyses......Page 334
Further Reading......Page 340
Why Do You Need Statistics?......Page 342
Graph the Data First......Page 343
Descriptive Statistics......Page 355
The Normal Distribution......Page 358
Discussion Questions......Page 362
Questions You Need Statistics to Help Answer......Page 364
Population versus Samples......Page 365
The Power of Averaging......Page 366
Making Comparisons and Assessing Progress......Page 368
Hypothesis Testing, Confidence Intervals, and p-Values......Page 372
Equivalence Testing......Page 397
Some Concerns with Significance Tests......Page 401
Key Points......Page 402
Discussion Questions......Page 403
Uncovering Relationships and Proving Cause and Effect......Page 404
Empirical Models......Page 408
ANOVA......Page 409
Model Building Using Regression......Page 413
Summary......Page 424
Key Points......Page 425
Discussion Questions......Page 426
Overview of DOE......Page 428
Important Questions to Answer before an Experiment......Page 433
Important Questions to Answer after Running the Experiment......Page 437
Some Important Considerations......Page 439
Types of Experiments......Page 442
A Simple Example......Page 445
Key Points......Page 447
Discussion Questions......Page 448
Using System Models and Noise to Improve Robustness......Page 450
Robustness Optimization of the Machining Process......Page 454
Additional Options for Optimization......Page 459
Discussion Questions......Page 463
Taguchiβs Contributions to Robust Design......Page 464
Building a Detailed Model versus Improving System Robustness......Page 466
Signal-to-Noise Ratio (S/N)......Page 470
Example Problem......Page 473
Key Points......Page 485
Discussion Questions......Page 487
The Tolerance Design Problem......Page 488
Controlling Variability......Page 491
How Do Tolerances Affect Product Performance?......Page 492
Steps for Tolerance Design......Page 495
Tolerances and the Cost of Quality......Page 497
Analysis of Tolerance Stacks......Page 499
Optimization of Functional Responses......Page 507
Discussion Questions......Page 510
Fundamental Reliability Functions......Page 512
Useful Life Distributions......Page 516
Key Points......Page 526
Discussion Questions......Page 527
Sources of Life Data......Page 528
Competing Failure Modes, Mixtures of Life Distributions, and the Importance of Failure Analysis......Page 529
Preventive Maintenance of Repairable Systems......Page 532
Fitting a Life Distribution to a Data Set......Page 534
Accelerated Life Testing (ALT)......Page 539
Mixed Failures from Time and Actuations......Page 543
Discussion Questions......Page 545
Section IV: Integration of Framework and Methods......Page 546
CPM and the Domains of Product Development......Page 548
Linking Customer Satisfaction and Critical Parameters......Page 552
Assessing Difficulty......Page 555
Assessing Importance......Page 558
Critical Parameters and Risk......Page 561
Critical Parameter Measurement......Page 564
Key Points......Page 565
Discussion Questions......Page 566
CHAPTER 24 An Illustration of Process Methods and Tools......Page 568
Advanced Product Planning......Page 569
Product Development......Page 571
Epilogue......Page 592
CHAPTER 25 Balancing Schedules, Budgets, and Business Risks......Page 594
Ongoing Attention to Product Development Capabilities......Page 596
Be a Student of the Process......Page 605
B......Page 606
C......Page 607
D......Page 608
F......Page 609
I......Page 610
M......Page 611
O......Page 612
P......Page 613
R......Page 614
S......Page 615
W......Page 616
BIBLIOGRAPHY......Page 618
A......Page 626
D......Page 627
E......Page 628
I......Page 629
N......Page 630
P......Page 631
R......Page 633
T......Page 635
Y......Page 636