Quality Strategy for Research and Development

MING-LI SHIU, PhD, works for Delta Electronics, Inc., where he executes strategic quality initiatives to revamp R&D operating models and improve technology and quality. Supervised by quality management guru, Dr. Noriaki Kano, in Japan, and working with corporations including Delta on engineering projects, he is an expert in Japanese methods of technology and product development.JUI-CHIN JIANG, PhD, is the Associate Professor and former chair of the Department of Industrial and Systems Engineering of Chung Yuan Christian University, Taiwan. He is Chair of the CYCU Quality Research Center and is a senior business consultant to corporations and government institutions.MAO-HSIUNG TU is the President of D&N Business Consulting Co., Ltd., and the founder and chairman of the Association of Quality Managers (AQM). He helped Philips (Taiwan) win the Deming Application Prize and the Japan Quality Medal in 1991 and 1997.

• Foreword xiby Yoji AkaoPreface xiii1 Introduction to Quality by Design 11.1 What Is Quality? 11.2 Why Quality by Design? 51.3 How to Design for Quality 51.4 New Product Development and QFD 61.4.1 Reflections on the Development of QFD 81.4.2 Reflections on the Evolution of NPD Philosophy 101.5 Technology Development and Functionality Design 121.6 Outline of This Book 13Part I Optimizing Design for Function 152 Quality Function Deployment 172.1 Historical Development and Definition of QFD 172.2 The Nature of QFD 192.3 Benefits of QFD 202.4 Two Dominant Approaches to QFD 212.4.1 Akao’s Matrix of Matrices Model 212.4.2 The Four-Matrix Model 252.5 Shortcomings of QFD 282.6 Review Comments on QFD 292.6.1 Comments on QFD’s Development Trends and Evolutions 292.6.2 Comments on QFD’s Shortcomings 372.6.3 Comments on QFD’s Applications 422.7 Concluding Remarks 443 Expanded System of QFD 453.1 Overview of EQFD System and Its Implementation Process 453.2 Thirty-Six Steps of the EQFD Implementation Process 51I. Business and Product Planning 51Ii. Technology Development Planning 54Iii. Request for Quotation (RFQ) 57Iv. Prototype Design 65V. Engineering Verification Test (EVT) 68Vi. Design Verification Test (DVT) 69Vii. Production Verification Test (PVT) 76VIII. Shop Floor Real-Time Management and Abnormality Management 773.3 Reinforcement of EQFD for the Original QFD 783.4 EQFD Application 923.4.1 Quality Deployment 923.4.2 Technology Deployment 923.4.3 Cost Deployment 1023.4.4 Reliability Deployment 1023.4.5 Shop Floor Management 1033.4.6 Summary 105Part II Optimizing Design for Functionality 1114 R&D Paradigm 1134.1 R&D Strategy as Prediction and Prevention 1134.2 Conventional Approach to R&D 1154.3 R&D Paradigm Shift 1205 Functionality Evaluation 1275.1 Energy Transformation and Technology Development 1275.2 Evaluation of Technology 1315.3 Signal-to-Noise Ratio 1325.3.1 Dynamic SN Ratio 1335.3.2 Static SN Ratio 1375.4 Comparative Assessment of Functionality 1415.4.1 Conventional Evaluation Indicators 1415.4.2 Using the SN Ratio 1465.5 Examples 1495.5.1 Two Measurement Systems 1495.5.2 Two Designs 1536 Functionality Design 1576.1 R&D and Robust Engineering 1576.2 Parameter Design for Robustness 1596.2.1 Key Concepts 1596.2.2 Key Tools 1636.2.3 Process Steps 1656.3 Common Problems of RE Application in Practice 1726.4 Robust Technology Development 1806.5 Case Studies 1936.5.1 Optimization of a Current–Voltage Conversion Circuit 1936.5.2 Robust Engineering of a Voltage Adjustment Component 2126.5.3 Accuracy Engineering of a Measurement System 2346.5.4 Stability Engineering of a Cutting Machine 2516.5.5 Summary 2697 Managing for Paradigm Shift 2837.1 Winning Quality-Based Technology Leadership 2837.2 Key Success Factors 2847.2.1 Technical Aspect 2867.2.2 Managerial Aspect 2877.3 Benefit to the Organization 2907.4 Slogan or Strategy? 290Part III Integration Strategy 2938 Structure for Design Activity Integration 2958.1 Universal Roadmap and Nine Tools for Design Engineering 2958.2 Integration of QFD and Other Breakthrough Strategies 3038.2.1 Simplified EQFD Model and Its Integration with DFX and DFSS 3048.2.2 Bos-qfd 3088.3 Integrated Process for Implementing QFD and RE 3128.4 Customer-Focused, Rationalized and Efficient R&D 316Appendix A Recommended Orthogonal Arrays for R&D 321Appendix B General Orthogonal Arrays 330References 349Index 357