Robustness development and reliability growth: value-adding strategies for new products and processes

641 Pages·2010·4.066 MB·English

by  Jewett, William S., King, John Paul

R D
OBUSTNESS EVELOPMENT AND
R G
ELIABILITY ROWTH
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R
OBUSTNESS
D
EVELOPMENT AND
R G
ELIABILITY ROWTH
V -A S N
ALUE DDING TRATEGIES FOR EW
P P
RODUCTS AND ROCESSES
John P. King
William S. Jewett
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Library of Congress Cataloging-in-Publication Data
King, John P., 1944-
Robustness development and reliability growth: value-adding strategies for new products and processes / John P. King and
William. S. Jewett.
p. cm.
Includes bibliographical references and index.
ISBN-10: 0-13-222551-4 (hardcover : alk. paper)
ISBN-13: 978-0-13-222551-9
1. New products—Management. 2. New products—Technological innovations.
3. Reliability (Engineering) 4. Product management. I. Jewett, William S. II. Title.
HF5415.153.K535 2010
658.5'75—dc22
2010003456
Copyright ©2010 Pearson Education, Inc.
All rights reserved. Printed in the United States of America. This publication is protected by copyright, and permission must be
obtained from the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by
any means, electronic, mechanical, photocopying, recording, or likewise. For information regarding permissions, write to:
Pearson Education, Inc.
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ISBN-13: 978-0-13-222551-9
ISBN-10: 0-13-222551-4
Text printed in the United States on recycled paper at Edwards Brothers, Ann Arbor, Michigan.
First printing, March 2010
To my wife, Linet, my son and daughter, Jonathan and Jennifer, my grandchildren,
Corey and Natalie, and my mother, Ann, with thanks for all their patience, love, and support.
John P. King
To my wife, Jane, and my daughter and son, Kristin and David. They kept me
encouraged and inspired throughout the project.
William S. Jewett
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Contents
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
Product Development 5
The Quality Improvement Movement 6
Management of Process Improvements 7
Clear and Compelling Call to Action 7
Internal Ownership 9
Top-Down Enablement 9
Bottom-Up Improvement 10
Objectives with Substantial Impacts 10
Early Measurable Results 11
Soft Causes of Poor Reliability and Durability 12
Inadequate Project Management Plans 13
Inadequate Development of System Integration and Robustness 13
Changing Product Requirements 14
Risk Management 16
Immature Baseline Technologies 16
Lack of Clear Expectations 17
Lack of a Disciplined Process 18
Inability to Speak Truth to Power 18
Failure to Implement Lessons Learned 19
Inadequate Development Budgets 19
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
Designed Quality 24
vii
viii Contents
Robustness 24
Durability 25
Manufactured Quality 26
The Taxonomy of a Failure 26
The Bathtub Curve 26
Early-Life Failures 27
Failures during Useful Life 28
Wear-out Failures at End of Life 29
Reliability Metrics 29
Reliability Is a Probability 31
The Anatomy of Quality Loss 33
Reliability as a Subjective Concept 34
Performance Variations 34
The Concept of Quality Loss 35
The Quality Loss Function 36
The Reduction of Performance Variations 39
Process of Parameter Design 40
Robustness Development 42
Key Points 44
Discussion Questions 44
CHAPTER 3 Strategies for Reliability Development 45
Are Better Strategies Important? 45
Reliability Growth Plot 46
Strategies for Ongoing Processes 48
Voice of the Customer (VOC) 48
Competitive Market Situation 49
Technology Development 50
Information Management 50
Strategies Specific to Product Development 51
System Architecture and Design Concepts 52
Reliability Development Strategies 52
Reliability Modeling 55
Project Management 55
Risk Management in Product Development 56
Capabilities of the Organization 57
Reliability Growth Rate 57
Assessment of Capabilities for Reliability Development 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
Phases and Gates 68
Contents ix
What’s the Problem? 68
Why Should Your Organization Have a Standardized
Development Process? 69
Published Development Processes 70
Process Documentation 71
Integration of Key Development Principles 71
DMAIC Six Sigma 71
Design for Six Sigma (DFSS) 72
Lean Product Development 72
Set-Based Design 73
Agile Development 73
Portfolio Management 75
A Process Model for Product Development 76
What Principles Affect the Layout of the Phased Activities? 76
Advanced Product-Planning Process 77
Technology Development Process 79
Technology Transfer 80
Product Development Process 81
Flexible Phases 82
What Questions Are Answered by Major Deliverables? 86
Key Principles for Robustness Development and Reliability Growth 87
Product Development Plan 87
Reliability Development Plan 89
The Model for a Product Development Process 89
Lessons-Learned Reviews 96
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
Defining Realistic Requirements for the Improvement
of Reliability and Durability 105
Selecting and Developing a Superior Product Concept 107
Identifying Potential Failure Modes and Their Levels of Severity 109
Developing Analytical and Empirical Models to Evaluate Designs 110
Developing Robustness to Prevent Problems in the Product Designs 111
Growing Reliability and Durability with Efficient Problem Solving 113
Balancing Performance and Costs through the Optimization of Tolerances 114
Improving Manufacturing Process Capabilities 114
The Role of Testing 116
Stress Tests 117
Reliability Growth Tests 117