Stage 3 - Detailed design (QFD and new product development)

Stage 3—Detailed design (QFD and new product development)

Phase 1: Innovation targets for parts and components

III - 1 Review charts from Segment II
A-1 Charts	Voice of customer, key quality characteristics, key system changes and approaches, competitive analyses
A-2 Charts	Voice of engineer, key quality characteristics
A-3	Subsystem trade-offs/conflicts
A-4	Key old subsystems, key new subsystems
B-1	Conflicts between voice of customer and voice of engineer
B-2	Cost targets—competitive analysis
B-3	Breakthrough targets for key quality characteristics
B-4	Subsystem quality characteristics, old and new cp targets, etc.
C-1, 2, 3, 4	System priority selection reasons
B-1, C-2, C-4	Cost reduction targets for functions, systems and subsystems
D-1, 2, 3, 4	Reliability priorities for subsystems based on customers, engineers, and quality characteristics
E-1, 2, 3, 4	New subsystem concept priorities based on voice of customers, engineers, and critical quality characteristics
F-1, 2, 3	Subsystem changes developed through value-engineering, factor analysis, finite element method, etc.
III - 2 A-4 Parts, components, and raw materials vs. key quality characteristics	Identify key parts, components, and raw materials to be improved based on strong relationship to key quality characteristics.
III - 3 B-4 Key parts, components, and raw materials vs. quality characteristics	Identify key functions, key quality characteristics, and capability indices for each of the key parts, components, and raw materials.

Phase 2: Innovation ideas for parts and components

III - 4 C-1 New technology vs. subsystems	Identify potential subsystem changes based on new technology.
III - 5 C-2 Subsystems vs. voice of engineer functions	Identify potential subsystem changes based on voice of the engineer (functions).
III - 6 C-3 Subsystems vs. key quality characteristics	Identify potential subsystem changes based on key quality characteristics.
III -7 C-4 Subsystems vs. parts, components, and raw materials	Identify priority parts, components, and raw materials for cost reduction.
III - 8 D-4 Parts, components, and raw material failure modes vs. parts, components, and raw materials	Prioritize development of parts, components, and raw material product FMEAs based on strong relationships with failure modes of same.
III - 9 E-1 New concepts for parts and components vs. customer demands	Preselect new concepts for parts and components based on meeting voice of the customer.
III - 10 E-2 New concepts for parts and components vs. voice of engineer	Preselect new concepts for parts and components based on meeting voice of the engineer.
III - 11 E-3 New concepts for parts and components vs. key quality characteristic	Preselect new concepts for parts and components based on meeting key quality characteristics.
III - 12 E-3 New concepts for parts and components summary	Identify strengths and weaknesses of new concepts for parts and components based on whether they are better or worse than existing product or best in class product when compared to customer demands, functions, and critical quality characteristics.

Phase 3: Innovation engineering for parts and components

III - 13 F-2 Reviewed dendogram	Draw a diagram of potential part, component, and raw material improvements based on data from steps II - 2 through II-12.
III - 14 F-1, F-2, F-3	Develop engineering breakthroughs on subsystems parts, and components using VE, PDPC, FEM, factor analysis, etc.
Task / Chart
III - 15 F-4 Summary of engineering breakthroughs	Purpose / Comments Summarize engineering breakthroughs regarding subsystems, parts, components and raw materials, cost savings vs. target, and items crucial for function, reliability and assembly.
III - 16 B-2 Review cost analysis based on engineering breakthroughs	Evaluate competitive cost position based on engineering breakthroughs. If acceptable, go on to III - 17. If not, review III - 9 through III - 14.
III - 17 A-4 Critical quality characteristics vs. new parts, components, and raw materials	Redo Chart A-4 based on new parts, components, and raw materials developed in steps III - 8 through III - 14.
III - 18 B-4 Functions, quality characteristics and Cp vs. key new parts, components, and raw materials	Analyze key new parts, components, and raw materials for function, quality characteristics, and Cp.

Phase 4: Manufacturing controls for parts and components

III - 19 G-1 QA Table	Identify key quality designs, quality characteristics, and reasons for key parts and components.
III - 20 G-2 Purchasing chart	Select best supplier based on quality, cost and other appropriate measures.
III - 21 G-3 Process planning chart	Identify the parts, characteristics and conditions of manufacturing (equipment and settings and control of the process).
III - 22 G-4 Process fault tree analysis	Identify potential process failure modes.
III - 23 G-5 Process failure mode and effect analysis	Identify the level of occurrence, severity, and detection of failure modes.
III - 24 G-6 QC Process chart	Identify the plan for process controls and inspection controls.

Stage 4—Prototype/Test: Revise manufacturing controls (QFD and new product development)

Task / Chart	Purpose / Comments
IV - 1 Review A, B, C, D, E, F charts from Phase III and make technical changes based on prototypes and tests. Save breakthroughs and inventions for next model unless savings is considerable, in which case seek appropriate waivers.
IV - 2 G-1 QA Table	Update QA table based on data from prototype/tests.
IV - 3 G-2 Purchasing chart	Update purchasing charts based on data from prototype/tests.
IV - 4 G-3 Process planning chart	Update process planning chart based on data from prototype/tests.
IV - 5 G-4 Process fault tree analysis	Update process fault tree analysis based on data from prototype/tests.
IV -6 G-5 Process failure mode and effect analysis	Update process FMEA based on data from prototype/tests.
IV - 7 G-6 QC Process chart	Update QC process based on data from prototype/tests.