ASQ RRD series webinar Robustness Thinking in Design for Reliability A Best Practice in Design for Reliability Dr. Matthew Hu SVP Engineering and Quality HAYLION Technologies March 11, 2021 https://attendee.gotowebinar.com/register/2625796907172545805 ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Popcorn Story Who Never Tasted Popcorn before? ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Not simply a REHASH of the lessons learned Microwaves popcorn-making is not simply a REHASH of the lessons learned in conventional way of popcorn-making, but a fundamentally different and proactive methodology. DO THINGS RIGHT (DMAIC Mind-Set) Conventional Way of Popcorn-making, fixing existing process, following conventional experience and procedures and … However, quality of popcorn is still heavily based on experience and … DO RIGHT THINGS (Design Thinking Mind-Set) Microwaves Way of Popcorn-making Right and Robust Technology, Good Quality of popcorn is not based (insensitive to) on experience ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Better, Faster and Cheaper ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Begin With the End in Mind (Covey - 7 Habits of Highly Effective People) • Will your customer always use your product under best conditions? • Will your product always be manufactured under best conditions? No ! Variation Happens!! ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Objectives • Define robustness • Explain product development using Robust Engineering versus traditional product development • Explain Robust Design for Reliability • Define Objective Function, Basic Function, and Ideal Function • Explain how Ideal Function and Two-step Optimization lead to robust technology development and achieve "Better, Cheaper, Faster" product development • Explain how to conduct a preliminary robustness assessment • Explain the value of robustness assessment • Case study in robust autonomous driving technology development ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Story in 1970 – SONY TV 0.3% Defects Customer satisfaction decreased when colour density deviated from target Made in Japan Target 100% Compliance X But American families liked Made in USA the TV made in Japan better ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Story in 2018– Self-Driving Vehicle Accident Arizona News https://www.theguardian.com/us-news/2020/sep/16/uber-self-driving-car-death-safety-driver-charged ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Reliability vs. Robustness Story ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Dr. Matthew Hu Introduction Dr. Deming 4-Day Seminar ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Un-Reliability Failure Rate Infant Mortality Wear-out period (Early failure period) Manufacturing Usage variation Inner variation & variation deterioration Best period Constant failure rate Time Production Processes Usage Environment Under Statistical Control? Under Statistical Control? Not Usually!! ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Control Methods and Tools In Bathtub Curve Infant Mortality Useful Life Wear Out Life Controls Design Controls Controls • Selection of Low Defect rate Parts, Joints, • Selecting high reliability Parts, Joints, • Selecting appropriate internal stress Interconnects, Fasteners, etc. Fasteners, Interconnects, etc. levels and materials to meet • Selection of Low Defect Rate Processes • Designing with the minimum number of expected time to failure or • Designing Within Process Capability Processes, Parts, Joints, Fasteners, replacement • Robust Design Interconnects, etc. • Designing with low stress levels on Parts, Tools Conformance Joints, Fasteners, Interconnects, etc. • Robust Design Tools Tools • DOE • DFA – Part count reduction • Reliability Data and Statistical Models • Reliability Data and Statistical Models • Critical Parameter Management • Physics of Failures – Failure Mechanisms • DFMEA/PFMEA/DFA/DFM • Physics of Failures – Failure Mechanisms • DOE • DOE • Statistical Tolerancing • Deterministic design • Prediction • Design and Process Capability (Cp, Cpk) • Prediction • Test to Failure/ALT • Mistake-Proofing, SPC, Control Plans • Test to Failure • HALT and HASS • HALT/ALT ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 The Challenge of Reliability Theory Assumptions Probability models under the assumption: • Processes under statistical control? – Probably not!!! • Lagging indictors of reliability performance – The design is created before testing – Usage feedback is even much later ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Reliability and Robustness (An Engineering Measure of Reliability) Target Target Requirement (.) (.) f f s s Quality Quality Loss Prob. Density, Prob. Density, Prob. Density, Prob. Density, m m Product Performance Product Performance Reliability: probability of a product performing Robustness: ability of a product to perform its its intended function for a specified life under intended function consistently in the presence of the operating conditions encountered. uncontrollable user environment (noise) during its intended life. In other words, the product is Q: How do you know the f(.) when a design is new? insensitive to noise. Computing probability of success requires Assessing robustness requires knowledge of m, s knowledge of m, s, f (.) ASQ Reliability and Risk Division series webinar 3/11/202114 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Back to Basic ◼ Work with the failure mechanisms ◼ And their relations to Variation! ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Reliability in a World Full of Variation Without Variation Variation Creates Problems: No World! - Deviations Life is Variation! - Disturbances - Noise ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 What is Robustness? Webster’s dictionary defines robustness as: • being powerfully built, sturdy • boisterous, rough • marked by richness and fullness Dr. Taguchi defines robustness as: • the state where the technology, product, or process performance is minimally sensitive to factors causing variability (either in the manufacturing or user’s environment) at the lowest cost. ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 A Simple Connector Reliability Design ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Typical DfR Process Used by Companies DFR Stages & Activities CONCEPT DESIGN DEVELOPMENT MANUFACTURING SUPPORT PHASE PHASE PHASE PHASE PHASE DEFINE IDENTIFY Reliability Key Reliability Risks Objectives ASSESS Proposed Design Reliability QUANTIFY Analyze & Improve Reliability ASSURE Reliability SUSTAIN Monitor & Control Reliability DFR STAGE ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Typical DfR Process Used by Companies DFR Stages & Activities CONCEPT DESIGN DEVELOPMENT MANUFACTURING SUPPORT PHASE PHASE PHASE PHASE PHASE DEFINE IDENTIFY Reliability Objectives Key Reliability Risks ASSESS Proposed Design Reliability QUANTIFY Analyze & Improve Reliability ASSURE Reliability SUSTAIN Monitor & Control Reliability DFR STAGE Life Data Demonstration Requirements & Change Point DOE FRACAS Goals Analysis Analysis Testing Accelerated Knowledge Environment & Robust Design Risk Assessment FMEA Testing Management Usage System Degradation Reliability Supplier Control Critical-to-Reliability Reliability Analysis Model Post Production (CTR) Simulation Failure Analysis PFMEA Warranty Data Requirements Baseline Reliability Critical Design Analysis Cascade Reliability Parameters Burn-in Allocation Management Manufacturing Prognostic Health ACTIVITIES Physics of Prognostic Capability Management Failure Health Control Plan & DFR Management Process Control ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Charts Prepared by: Matthew Hu The Challenge of Reliability Design at The Lowest Cost Reliability Efforts included Results − d/pFMEA − Connectors were still − HALT disconnected as unexpected − Design of Experiments − One of the main reasons for − 8D an automotive safety recall − Weibull analysis conducted − SOP developed − SPC implemented − Operator trained ASQ Reliability and Risk Division series webinar 3/11/2021 Dr. Matthew Hu, [email protected]; Phone: 281-299-4230 Conventional Approach • Design-Test-Fix • No cost integration • Test parts under severe conditions • Lack of leading indictor • Ignore deterioration,