79_红带_设计阶段 RB_Design_Tollgate.ppt

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1、8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,1,Design Tollgate设计阶段 Design Module设计模块,Revision 修订本5.1:8-19-06,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,2,4.0 设计方案,1.0 定义,2.0 测量,3.0 分析,4.0 设计,5.0 验证,It

2、ems in tan are also DMAIC tasks,and are not specifically re-taught in the DFSS program,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,3,4.0 Design Solution,1.0 Define,2.0 Measure,3.0 Analyze,4.0 Design,5.0 Verify,Items in tan are also DMAIC tasks,and ar

3、e not specifically re-taught in the DFSS program,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,4,Design Summary设计总结,The activities of Red Belts are to provide design support and are to actively support and drive solutions to“Design Issues”and“Pugh Matr

4、ix”trade off decisions as soon as possible to reduce the risk to the project.The success of every project depends on the sub team contributions红带培训旨在于提供设计支持并且积极地支持和推动“设计问题”的解决，以及利用皮尤矩阵对方案进行对比研究以降低项目的风险。每个项目的成功取决于团队成员的贡献。Key Questions Answered in this step:此步骤关键问题的解答：What are the key design elements

5、that the final design must include?最终设计必须包括哪些关键的设计因素：How do we prioritize these design elements?如何优先排列这些设计因素?How can we distribute the design work among sub-teams?如何分配工作给设计团队？How do we ensure that these sub-teams communicate effectively with each other during the design process?如何确保设计团队成员在设计过程中进行了有效

6、地交流？At what point do we“freeze”the design?在哪个结点上，可以“冻结”设计？How do we test the design to ensure that it will work before implementation?在设计实施之前，通过怎么的试验确保该设计没有问题？How do we identify weak points in the design that may be susceptible to failure?如何界定设计中可能会导致失效的缺点/弱点？How do we plan to pilot to ensure that i

7、t is realistic and produces meaningful results?怎样计划并确保设计产品的可行性并且产出好的产品？,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,5,DESIGN Tollgate Review Questions设计阶段评审问题,Customer Requirements客户要求Have the customer requirements changed?客户要求有无变化？Describe the propo

8、sed design and its predicted capability.描述提议的设计方案和预测的能力？Internal Requirements内部要求How many intermediate levels of design are necessary before all decisions are made?在决定之前，有多少中等水平的设计是必须的？What are the key elements of the design that are fulfilled by the work that has been completed?在完成的工作中，实现了哪些关键设计因素？

9、How did we prioritize the design work?如何优先排列设计工作？How do we prioritize the work into sub-teams?如何优先排列设计团队的工作？How do we ensure that the sub teams communicate effectively with each other during the design process?如何确保设计团队成员在设计过程中进行了有效地交流？How do we test the design on paper to get a degree of confidence

10、that it will work before implementation?在设计实施之前，通过怎么的试验，可有有信心的确保该设计没有问题？How do we identify weak points in the design that may be susceptible to failure?如何界定设计中可能会导致失效的缺点/弱点？How do we test the design after it is complete?设计完成后，如何试验该设计？Are the proposed benefits still expected?预计的效益是否还存在？What is the es

11、timated investment?估计的投资是多少？When will the project be completed?项目何时完成？Risk Management风险管理What items in the risk abatement plan are unresolved?风险计划中的哪些项目还没有解决？What will the early warning plan have to include?预警计划中应该包括哪些内容？Other其他Summarize the Robust Design&Tolerance Design Activities.总结稳健设计和公差设计活动Sum

12、marize the part/raw material procurement plan and manufacturing plan.总结部件/原材料采购计划和生产计划.,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,6,Design Tollgate 设计阶段,Goal目标Develop high level detailed design 开发高层次详细设计Test Design Components设计部件试验Complete Pilot Te

13、sting完成试生产试验Prepare for full scale implementation准备全面生产Output输出Final Selection of Design Alternatives 最终确定设计选择Tested high level design 高层次设计试验完成Tested detail design详细设计试验完成Plans for process control流程控制计划Completed design reviews设计评审完成Critical Checkpoints for High Level Design 高层次设计关键的检查点Clear definit

14、ion of the design alternatives 明确的供选设计方案定义Concept review outputs documented and Pugh Matrix Completed设计方案评审输出和皮尤矩阵完成High level design requirements updated更新高层次设计要求Cost/benefit analysis results documented 成本/效益分析结果完成High risk areas identified and risk mitigation plans implemented高风险领域确定和风险降低计划实施Paper

15、 Design of Key Elements Complete.关键设计因素完成Pilot results are checked against performance requirements for the CTQ Matrix for flow down achievement.性能要求和设计结果对比完成，准备关键质量特性表格。,Critical Checkpoints of the Detailed Design详细设计的关键检查点Design fully developed and tested 全面设计和试验完成FMEA/EMEA/Simulation analysis Com

16、pleted FMEA/EMEA 模拟分析完成Solutions designed for vulnerable elements 弱点因素的解决方案设计完成Process Management system variables identified 确定了流程管理系统变量Process Management System Details Documented.流程管理系统详细文件完成Process Management Design Approval 流程管理设计批准Relevant Tools相关工具QFD质量功能展开Simulation模拟软件Rapid Prototyping快速样机F

17、MEA/EMEA Summary FMEA/EMEA 总结Design Scorecards设计分数卡Planning Tools计划工具Design Reviews设计评审Check sheets检查表CTQ Matrix关键质量特性表格Production Reviews生产评审Kaizen Events改善工具,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,7,10.0 Design Summary设计总结,B.Pilot test results

18、 are:试生产试验结果：Major Issues Found And Resolved 主要问题的发现与解决Issues list/8D问题列表/8DFMEA Actions Implemented失效模式影响分析实施Pilot Test Results试生产试验结果Improvements verified改善验证完成New system performance新系统的性能Documented system or process maps.系统图，流程图完成FMEA 失效模式影响分析Tolerance Analysis Results公差分析结果Design Scorecard Updat

19、e设计分数卡更新,The recommended design features推荐的设计特色Targets and Specifications 目标和技术参数2.Performance Improvements 性能提高3.Costs and Margin成本和利润,C.Tools Used:工具Process/System maps流程图/系统图QFD质量功能展开Prioritization Matrix优先管理矩阵Cost-benefit analysis成本效益分析DOEs实验设计Descriptive Statistics描述性统计Process capability流程能力Pug

20、h Matrix皮尤矩阵8D Issues Lists 8D-问题列表Pilot test plan试生产试验计划Graphical analysis图解分析,What tools did you use here.你用了什么工具？,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,8,设计阶段团队练习,目的：运用投石器，实施团队的解决方案以提高打到目标的预测能力，完成打到目标的任务。通过不同的距离，“X”角度和“Y”距离，利用量具重复性和再现性和回归分析工

21、具分析结果，演示能够提高投石器打到目标的能力。说明：利用在皮尤矩阵选择的结果，以及在“创意箱”中选择的创意或想法。改善投石器.这些改善应该和你们在皮尤矩阵中决定是一致的。通过正确的运用量具重复性和再现性，以演示测量系统的改善。完成结果的回归分析，并确定结果的预测公式。跟踪你们组在实验中出现的问题和结果最终确定一个解决方案。更新红带报告DMADV幻灯片文件：你的计划是什么？你是如何分工的？汇报你的解决方案取得的怎样的结果？通过量具重复性和再现性中显示的数据，应该改善测量系统哪些地方？在精确度方面，有些地方应该改善？在实验过程和完成目标时，你遇到了哪些问题？,60 分钟,.Lesson Plans

22、RB Storyboard.xls,Team Tools,总结活动挂图记事板,5 分钟,改善 20 分钟,25 分钟,Conduct Correctly&Keep Blind,8/19/2006 Design,Revision 5.1 For Internal Use Only-All Rights Reserved-The Manitowoc Company,9,Design Tollgate Team Challenge Exercise,Objective:Implement the solutions for improving the prediction capability of

23、 hitting targets with the catapult.Demonstrate solutions that will improve the ability of the catapult to hit targets at various distances between“x”angles What was your plan?How did you divide the work required?Report out how well your solutions achieved the results.What improvements do you see in

24、the measurement system shown in your Gage R&R?What improvements in accuracy do you see?What problems did you have conducting your experiment and achieving the results?,60 Minutes,.Lesson PlansRB Storyboard.xls,Team Tools,SummaryFlip ChartStoryBoard,5 minutes,TrialImprovements 20 minutes,25 minutes,Conduct Correctly&Keep Blind,