© G. A. Motter, 2006 & 2008

Function Definition

A Powerful Problem or OpportunityAnalysis Technique

© G. A. Motter, 2006 & 2008

© G. A. Motter, 2006 & 2008

Test & ValidateAssess Performance, Reliability, Mfg, ...

OK

Capture & Analyze Voice of the CustomerIdentify Critical Customer Requirements (CCRs)&

Establish System Level Engineering Specifications

Design for ManufacturabilityMinimize Sensitivity to Mfg Variations

Design for Robust PerformanceMinimize Sensitivity to Design & Operating Variations

Predict QualityPredict Iterate to Meet Quality Target

Identify System Design ConceptDetermine System Functionality

Flow Down of CCRs to Sub-Assemblies and parts

Develop Detailed DesignRelate CCRs (Ys) to Design Parameters (x’s)

OK

Deliver to Customer

Optimizefor 6

Validate

Design

IdentifyCCRs

Define

Define the ProjectBusiness Case, Opportunity Statement, Goal,

Scope and Boundaries

Typical

DFSS

Process

Source: Design for Six Sigma, K. Yang

© G. A. Motter, 2006 & 2008

Objectives

• Learn “Best Practices” to Define Functions

• Identify Basic and Secondary Functions

• Develop a FAST Diagram

• Intro. to Value Engineering

• Assign Homework

FAST: Function Analysis System Technique

© G. A. Motter, 2006 & 2008

Function Definition

• A description of a product expressed as an ActiveVerb and a Measurable Noun

• Provides a complete understanding of the basicreason(s) something exist

• Explore new ways to deliver Customer Satisfaction– Improved performance

– Lower cost

© G. A. Motter, 2006 & 2008

Steps to Function Definition

1. Define Project Scope

2. Define the Functions

3. Construct the FAST diagram

4. Perform FAST diagram logic checks

Source: Value Management, J. Kaufman

FAST = Function Analysis System technique

© G. A. Motter, 2006 & 2008

1.) Project Scope is a Lead Pencil

LEAD

PAINT

BODY

BAND

ERASER

PENCIL

COMPONENTS

This product couldThis product couldbe anything:be anything:•• Power SupplyPower Supply

•• Circuit BreakerCircuit Breaker•• Data BaseData Base•• SoftwareSoftware•• Radar SetRadar Set•• etc.etc.

Source: Value Management, J. Kaufman

© G. A. Motter, 2006 & 2008

2.) Define the Functions for your Project

Functions are defined in two word phrases

• Active Verb:

– Describes the specific action we plan to carry out to achieve our intendedpurpose

• Measurable Noun

– Defines the object on which the action operates

• Any Verb may be combined with any Noun to describe adesired Function

Acid Test – “Does it describe what somethingactually does in the system under study?”

© G. A. Motter, 2006 & 2008

Verbose Descriptions Indicate Lack ofDesign Understanding

Reduce Size

Educate Students

Create Image

Control Deflection

Collect Dirt

Collect Data

Attract Attention

Remove CD

Stop Automobile

Steer Automobile

Start Engine

Suppress Noise

Cut Grass

Transmit Information

Save Time

Reward Achievement

Tighten Bolt

Protect Children

Prevent Contamination

Maintain Clearance

Increase Incentive

Establish Budget

© G. A. Motter, 2006 & 2008

Verbs to Avoid

Passive and Indirect Verbs

Goal-Like Verbs

AttendReview

PrepareFurnishSupply

IsGiveProvide

Economize

MinimizePresent

PrioritizeMaximizeLeast

Optimize“ize” wordsImprove

© G. A. Motter, 2006 & 2008

Tips for Active Expressions

• Important to use active Verbs rather than passive Verbs

• To change passive description to active, try using the nounas the verb and select another noun

Resolve ProblemDetermine Resolution

Budget ExpensesSubmit Budget

Exhibit ProductsDevelop Exhibits

Approve ProceduresSeek Approval

Support WeightProvide Support

ActivePassive

Functions are intended to be taken literally as we attempt to bringclarity in describing WHAT a system actually does

Exam

ple

s

Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping

© G. A. Motter, 2006 & 2008

Function Description Of A Lead Pencil

PencilComponents

Description

ERASER Remove Marks

BAND Secure EraserImprove Appearance

BODY Support LeadTransmit Force

Accommodate Grip

PAINT Protect WoodImprove Appearance

Display Information

Deliver Message

LEAD Make Marks

Source: Value Management, J. Kaufman

© G. A. Motter, 2006 & 2008

3.) Every Design has Basic andSecondary Functions

Basic Function:• Principal reason for the product’s existence

• Has value to the Customer

• Loss of Basic Function results in total loss of market value forthe design

• May be Performance or Esteem based

Secondary Function:• Assist in, or necessary for, the realization of a Basic Function

• Targets for modification and/or elimination to:

– Reduce cost

– Reduce design complexity

– Achieve Breakthrough in design

Source: Value Management, J. Kaufman

© G. A. Motter, 2006 & 2008

Basic and Secondary Functions Of A Pencil

PencilComponents

Description Functions

(Basic or Secondary)

ERASER Remove Marks Secondary

BAND Secure Eraser SecondaryImprove Appearance Secondary

BODY Support Lead SecondaryTransmit Force Secondary

Accommodate Grip Secondary

PAINT Protect Wood SecondaryImprove Appearance Secondary

Display Information Secondary

Deliver Message Secondary

LEAD Make Marks Basic

Source: Value Management, J. Kaufman

Why someonebuys a pencil

© G. A. Motter, 2006 & 2008

3) Construct the FAST Diagram

Why do a FAST Diagram?

– Help understand whichFunctions provide the bestopportunities to beeliminated, or improved, todeliver the BasicFunction(s)

FAST Diagram

– Visual layout (Tree Diagram) of theproduct’s Functions

– Starts with the Basic Function, and buildsto the right with supporting or SecondaryFunctions

© G. A. Motter, 2006 & 2008

Construct FAST Diagram Left to Right,and Check it Right to Left

1. Identify what you feel is the Basic Function.2. Place Secondary Functions to the right of the Basic Function. Ask the

question: “How is this Function actually accomplished?”3. Check the FAST diagram by starting at the right and working left. Ask the

question: “Why must this Function be performed?”

Basic Function

Secondary Function

Secondary Function

Secondary Function

Secondary Function

Secondary Function

Source: Value Management, J. Kaufman

AND logic

OR logic

Ask How ?

Ask Why ?

© G. A. Motter, 2006 & 2008

Example: Lead Pencil FAST Diagram

KeepRecords

MaintainInformation

RecordInformation

MakeMarks

DepositMedium

ApplyPressure

SupportLead

ProtectWood

SecureEraser

TransmitForce

Accommodate

Grip

CorrectInformation

RemoveMarks

AbsorbMedium

ApplyPressure

RubEraser

ImproveAppearance

DisplayInformation

Ask How ?

Ask Why ?

© G. A. Motter, 2006 & 2008

Example Mouse Trap

Objective: Eliminate Mice

KillMouse

StrikeMouse

ReleaseStriker

TripTrigger

ArmTrap

PositionStriker

SetTrigger

BaitTrap

AttractMouse

ReleaseEnergy

StoreEnergy

CompressSpring

Ask Why ?

Ask How ?

© G. A. Motter, 2006 & 2008

ProduceSlicedHam

EnsureFlavor

EnhanceAppearance

FabricateSlices

Space Meat Length

Determine MeatWeight

Remove Fat

Remove Casing

Form Meat

Remove Air Bubbles

Adjust Meat Color

Spread Flavoring

Sliced Ham Process

Source: Function Analysis, K. Akiyama, pg 207

Example: Inject Brine

Retain Brine

AddColoring(to Meat)

TenderizeMeat

Lower MeatTemp

Fix MeatThickness

Add Flavoring

© G. A. Motter, 2006 & 2008

Four Rules of FunctionDefinition

1. Once defined, the Basic Function cannot change; itbecomes the principle work the system does.Example: A flashlight is expected to emit light

2. The cost contribution of a Basic Function is usuallyminimal percentage of total cost

3. Can not sell supporting Secondary Functions withoutperforming the Basic Function satisfactorily

4. Loss of Basic Function(s) causes loss of marketvalue. Example a Rolex watch that does not displaycorrect time

© G. A. Motter, 2006 & 2008

4.) FAST Diagram LogicChecks

Double check tree diagram “How?” and “Why?” logic.

Identify possible Secondary Functions for elimination?

Test by removing Secondary Function, and ask the“How ?” and “Why ?” logic questions.

Check “AND” logic and “OR” logic diagramming.

Ensure project Scope lines are clearly drawn.

© G. A. Motter, 2006 & 2008

Cost Function Matrix is Workhorse ofValue Engineering

Functions come fromdetailed level of FASTDiagram

Total

%

Operations, Parts,

Assembly

Total

Cost

Functions (V-N)

Operations, Parts, andassemblies come from:

- Block diagram- Process Map- Logic Diagram- Value chain

© G. A. Motter, 2006 & 2008

Cost – Function Matrix IdentifiesAreas of Opportunity

Steps to Create Matrix:

1.) List major operations, parts, or assemblies in lefthand column

2.) List total cost for each group in adjacent column3.) Place Functions across top from FAST Diagram4.) Identify Functions contributing to each line of cost

(indicate with dot in cell)5.) Determine portion of cost associated with each

function6.) Sum Functional cost7.) Calculate Function %8.) Show Function % on FAST diagram

© G. A. Motter, 2006 & 2008

Example: International North Atlantic Ice Patrol

• Formed in 1913• Result of Titanic sinkingApril 14, 1912

• Iceberg condition data collected by• Fixed wing aircraft• Buoys

• Report warnings at 9 pmeach day in “plain, conciseEnglish” during ice seasonfrom February thru July.

© G. A. Motter, 2006 & 2008

Example:International Ice

Patrol

Source: Value - Its Measurement, Design, and Management by M.L. Shillito Fig 7.7

Send IcebergWarnings

TransmitRadio

Messages

CompileMessages

LocateIcebergs

PredictIcebergPosition

PurchaseSensors

HireOperators

MoveOperators

MoveSensors

Receive ShipData

Collect Data

Predict IceDrift

OperateRadio

EstablishStation

Ask How ?

Ask Why ?

© G. A. Motter, 2006 & 2008

Example: International Ice PatrolCost-Function Matrix

Note: Cost in 1983 dollarsSource: Value – Its Measurement, Design, and Management by M.L. Shillito, Fig 7.8

Total

Cost $M Pu

rch

ase

Sen

so

rs

Hir

eO

pera

tors

Mo

ve

Op

era

tors

Mo

ve

Sen

so

rs

Receiv

eS

hip

Data

Co

llect

Data

Pre

dic

tD

rift

Esta

bli

sh

Sta

tio

ns

Op

era

te

Tra

nsm

itte

r

Aircraft Personel 705 235 235 235

Fuel 494 247 247

Aircraft Maintenance 490 245 245

Aircraft Op. Support 152 76 76

Office Staff 224 56 56 56 56

Travel/Lodging 50

Leasing 5 1 4

Bouys 63 63

Radar Film 13 13

Misc. 5 5

Admin. 480 120 120 120 120

Total $2,681 77 235 853 803 176 176 176 9 176

% 100 2.9 8.8 32 30 6.5 6.5 6.5 0.3 6.5

© G. A. Motter, 2006 & 2008

Example: International Ice Patrol

Source: Value - Its Measurement, Design, and Management by M.L. Shillito Fig 7.7

Send IcebergWarnings

TransmitRadio

Messages

CompileMessages

LocateIcebergs

PredictIcebergPosition

PurchaseSensors

HireOperators

MoveOperators

MoveSensors

Receive ShipData

Collect Data

Predict IceDrift

OperateRadio

EstablishStation

$2,496,000

$185,000

$2,056,000

$440,000

$2,681,000(1983)

2.9%

8.8%

32%

30.0%

6.5%

6.5%

6.5%

6.5%

0.3%

Ask How ?

Ask Why ?

Target for costreduction

© G. A. Motter, 2006 & 2008

Homework Assignment

Objective

• Develop a FAST Diagram for your ECE 480 Senior Design Project

Instructions

• Provide a few sentences describing your Senior Design Projectdesign objectives to orient me in grading this homework assignment

• Follow Step-By-Step process in slides

• Refer to examples in Slides and Appendix

• Refer to Appendix for list of useful Verbs and Nouns

• Only diagram a maximum of 3 levels of Secondary Functions beyondBasic Function

Deliverables

• Typed FAST Diagram in Microsoft Word, Excel, or PowerPoint foreach Team

• E-Mail Diagram to G. Motter at sail1070@Yahoo.com and to Dr.Goodman

Due Date

• October 6, 2008

© G. A. Motter, 2006 & 2008

© G. A. Motter, 2006 & 2008

Questions?

© G. A. Motter, 2006 & 2008

Appendix

Classical Text Book Examples

© G. A. Motter, 2006 & 2008

Useful Verbs in Describing Functions

SelectLocateDevelop

RotateIsolateDestroy

ReverseInvertCool

RetainInsulateConvert

ResistIncreaseControl

VerifyRemoveImplementConduct

UseReduceHeatContain

TransportRecordHardenConfirm

TransmitRecommendFreezeCombine

TestProtectExtendCollect

SupportPreventExpandCreate

StorePositionEvaluateAttach

StartObtainEliminateArrange

SeparateMeasureDistributeAnalyze

SenseMaintainDisplayAdd

© G. A. Motter, 2006 & 2008 Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping

© G. A. Motter, 2006 & 2008

Useful Nouns in Describing Functions

TextureMotionExpansion

TemperatureMoistureEnvironment

StressMobilityEnergy

SpaceMixtureEnclosure

SoundMaterialDistance

WeightSolidLengthCurrent

WearSizeInformationComponent

WaterShapeIndicationCommunication

WasteRotationHumidityComfort

VoltageResistanceHeatColor

VolumeResistanceGasCold

VibrationProtectionFrictionAtmosphere

VehiclePressureFrequencyAssembly

TorqueOpeningForceArea

TimeNoiseFluidAir

© G. A. Motter, 2006 & 2008 Source: Stimulating Innovation in Products and Service with Function Analysis and Mapping

© G. A. Motter, 2006 & 2008

Ask Why ?LocateSheet

Pierce Sheet

AdjustHoles

Collect Waste

Attract UserProhibit Rust

Protect Work Surface

Drop Holes

Collect Holes

Locate Punch Assembly

Retract Punch

Guide Punch

Drive Punch

Support SheetPaper Punch

Source: Acquiring, Processing, and Deploying the Voice of the Customer, M. Shillito, pg 74

Example:

ProduceHoles

BasicFunction

Ask How ?

Scope

OrganizePaper

Task

Decorate Surface

© G. A. Motter, 2006 & 2008

FAST Model is complete when Customer Needs can beMapped to Secondary Functions

SecondaryFunction

1. Need2. Need

SecondaryFunction

1. Need2. Need3. Need

SecondaryFunction

1. Need2. Need

CustomerTask

BasicFunction

SF

SF

1. Need

SF

SF

SF

SF

1. Need

Ask How ?

Ask Why ?

© G. A. Motter, 2006 & 2008

Mapping of Voice Of Customer to FunctionsExample: Paper Punch

Locate Sheet• Easy to insert• Stays in place

Pierce Sheet• Easy to press• Won’t hurt hand• Pierce multiple sheets• Non-jamming

Adjust Hole (location)• Easy access to assembly• Easy to position• Finger tight• Stays in place

Collect Waste• Holds large quantity of holes• Holes won’t fall out• Easy to clean

ProduceHoles

© G. A. Motter, 2006 & 2008 Source: Function Analysis, K. Akiyama, pg 55

Function Tree - Flashlight

Ask How ?

Ask Why ?Example:

Convert Electricityto Light

Open/closecircuit

Form Circuit

Store ElectricalEnergy

Reflect Light

Adsorb Force

Fit Grip

Collect Light

Hold Bulb

Protect Bulb

Send Current

Generate Light

House Parts

IlluminateSurroundings

Hold Body

RetainAppearance

BasicBasicFunctionFunction

© G. A. Motter, 2006 & 2008

Verbose Descriptions Indicate Lack ofDesign Understanding

Organize DataSpreadsheet

Convert CurrentRectifier

Store InformationFlash Memory

Limit CurrentFuse

Illuminate SurroundingsLED Array

Verb Noun

Function DefinitionObject

© G. A. Motter, 2006 & 2008

Appendix

Past ECE 480 Project Examples

© G. A. Motter, 2006 & 2008

Detect IceLevel

OutputHeight

TaskBasic

Function

DisplayLED

DecodeImage

SenseEnvironment

HaveInformation

Have PowerSource

DecodeInformation

TransferImage

HaveAlgorithm

CapturePicture

Emit Light

Have PowerSource

Time ImageCapture

Have IceBin

PrepareCamera

Havealgorithm

CloseFreezer Door

Stop IceMaker

Refrigerator IceLevel Detection

© G. A. Motter, 2006 & 2008

MeasureHeight

Locate BrimOf Object

DetermineDistance

ActivateSensingSystem

DetectObject

Collect Data

UseAlgorithm

Send Signal

CalculateVoltageChange

DisplayObjectHeight

(inches)

Convert AnalogSignal to Digital

Signal

Implementand Run

Code

© G. A. Motter, 2006 & 2008

Team 13 Digital Answering MachineFAST Diagram

Detect Rings Connect Line

Answer Phone Detect Dial-tone Disconnect Line

Receive Messages Store Messages Record Audio Digitize Signal

Basic Function Secondary FunctionsStore Date/time

Volume Control Amplify Audio

Playback Messages Convert Message Retrieve Message

Display Date/time Retrieve Date/time

© G. A. Motter, 2006 & 2008

ECE480Active EMI Filter

ReduceConducted

Noise

ReduceLow Frequency

Noise

ReduceHigh Frequency

Noise

SenseNoise

AmplifyNoise

Correct For NoiseError

Combine withExisting Noise

Increase SeriesImpedance at High

Frequencies

Short HighFrequency Noise

To Ground

Couple to FilterInput

MeasureSystem Error

CompensateAmplifierFor Error

UseInductors

UseCapacitors

Cancel Currents

Cancel Voltages

Design EMI Filter forAutomotiveApplication

Pass DC throughFilter

© G. A. Motter, 2006 & 2008