Design for DFX April 15, 2015 Mark RockwellGeno Scalcucci John MurphyDrew Kamerzell A guide to creating effective documentation for all DFX’s

Design for DFX

April 15, 2015Mark Rockwell Geno ScalcucciJohn Murphy Drew Kamerzell

A guide to creating effective documentation for all DFX’s

How this lesson works

Ingredients Case Study

Explanation of purpose and goals of the ingredient

DF Poka Yoke reimagined per suggested DF DFX structure

Description of how a DFX case

study should look

Demonstration of ingredient for

explaining DF DFX

Good/poor examples pulled

from existing DFX lessons

Scope

Lesson Goals

The Problem

Reflection on the process

DF DFX Goals

• Create a structured guideline that can be applicable to all DFX’s with allowance for easier use, understanding, and comprehension by future readers.

• Streamline the DFX lesson format to encourage better edification and course experience in future classes.

• Encapsulate and discuss the entire development process as it applies to DFX, involving as many departments within an organization as needed.

• This DF”X” presentation will be used as a guideline for future users creating coursework for DFX.

Current DFX Problem

• Existing DFX presentations were created by many different people with different creative direction and therefore very different styles.

• This forces users to recalibrate their thought processes as they traverse between DFX subjects and impedes the ability of the reader to absorb the content.

• Different formats and presentation structure leaves holes in the subject matter and inconsistency in the way the subject matter is presented.

Proposed Solution

• Standardization makes the presentations more readable for users, maintains a consistent arrangement of core information, and facilitates absorption of information when reading/reviewing multiple DFX’s.

• The key ingredients every DFX will need to effectively reach the target users are:o How the specified DFX is used o How to apply the DFX lesson in practice

DF DFX Assumptions

• 85% of the reading audience are graduate students with little or no experience with defined “X”’s.

• DFX should read like a book presented in Google Sheets.

• These documents are not an aid to a presentation but a means to educate

• They are standalone documents with linked references

• NO PROPRIETARY INFORMATION!

DF DFX Course Outline

● Define The X● Define the Design for X● Define how you Design for X● What are the measures of failure and success● Highlight simple real world examples● Why you Care● How to Apply DFX● Key DFX Considerations● Case Study(s)

Define the X: Slide Goals

• Summarize what is the X to be outlined

• High-level definitions of the X

• Cite from industry/sources other definitions for the X for different perspectives on the X

Define the X: Examples

• Good Examples o DF Serviceability: the ability of a technician to

service a particular component of a system (IE, an automobile transmission or computer hard drive).

• Bad Exampleso No definition giveno DF Poka-yoke: “is Japanese for mistake proofing”

How does this help the reader? Not cited.

DEFINE DFX

• “Under the label Design for X, a wide collection of specific design guidelines are summarized. Each design guideline addresses a particular issue that is caused by, or affects the characteristics of a product. The design guidelines themselves usually propose an approach and corresponding methods that may help to generate and apply technical knowledge in order to control, improve, or even to invent particular characteristics of a product”1

DEFINE DFX

• DFX is a guideline that allows the user to design for the X.

• DFX is designing to prevent a failure or an undesirable condition of the particular “X”.

• DFX is making sure that the design functions as intended in all circumstances


● Define The X● Define the Design for X● Define how you Design for X● Measuring DFX Failure and Success● Simple Real World Examples● Why you Care● How to Apply DFX● Key DFX Considerations● Case Studies

Define “Design for X”: Slide Goals

• Outline what it means to design for the chosen X

• It is important to capture not only what the X is but what Designing for X entails

• Why is important to design for this X - what needs to accomplished or what error state needs to be avoided

• It is important to give a good definition that not only defines the “design for X” but delineates between the definition of the X and the design for X

• Good Example:o DF Environment: A systematic consideration of

design performance with respect to environmental, health, and safety objectives, over the full product and process life cycle

• Bad Example o Many DFX’s gloss over this part of the lesson

assuming defining the X is good enough. However, just because someone knows what the testability is doesn't mean they are able to design for testability.

Define “Design for X”: Examples

What is Design for Design for X

• The organization of information o Create a DFX that formalizes how to create or

reformat a DFX presentation.

o The “X’ in DF X suggests that the X is a variable term that can be substituted with any number of “functions”: Assembly, Cost, Fabrication, Manufacturing, Reliability, Serviceability Etc.



How to Design for X

• This slide should describe to the reader how to design for the X. It is a high level summary of the process. The detailed step by step process will be described in the How to Apply DFX section. You as the expert should take into account all appropriate steps needed to design the X properly and describe in detail with guidelines for the reader to follow. All tools and techniques needed to DFX are described. Any additional DFX’s that should be worked in parallel are also noted.

How to Design for X

• GOODo The reader can clearly understand the DFX process. They can

follow the DFX process after reading the case study. The reader should be able to describe and explain the process after reading the DFX.

• POORo The DFX contains no description of how to design for X.o The reader gained no knowledge or ability to explain the X.

How to Design for X: DFX

These guidelines should be used when designing for DFX

• The DFX should define the X

• The DFX should define the design for X

• The DFX should give examples of failure and success

• The DFX should provide real world examples of the X

• The DFX should provide reasons for why you care about the design for X

• The DFX should provide detailed process of how to apply the DFX

• The DFX should provide key considerations

• The DFX should include case study examples


● Define The X● Define the Design for X● Define how you Design for X● Measuring DFX Failure and Success● Simple Real World Examples● Why You Care● How to Apply DFX● Key DFX Considerations● Case Studies

Measuring failure and success: Slide Goals

• It is important to indicate what determines good or poor DFX. These measures supply a metric for a user to objectively indicate their strength or weakness in the implementation of a particular DFX.

• Measures of success and failure vary greatly between different DFX’s, take into considerations the different stakeholders involved with your particular DFX and ask questions like these:o How is a stakeholder’s interaction with a design changed based on

the selected “X”? o Is there a tangible difference versus designs in existence? Why?

• The answer to why will lead to measurable levels of success that can be used to indicate success/failure.

• Degrees of success/failure should be objectively measurable

• In addition, when all DFX’s have objective metrics a user will be able to access their design and progress at different points in their process and determine where the product/concept is strong/weak and what elements have opportunity for improvement.

Measuring failure and success: Examples

• Goodo DF Ergonomics: Discussion of objective

measurements needed for Anthropometrics (slide 24). Discussion on objective measures that have been developed over time to determine if a concept has good design for ergonomics elements

• Pooro Objective measures not giveno Subjective or muscle memory examples provided. o Missing examples of how someone with little

experience could review a concept and determine how well/poor a particular DFX is implemented

Measuring failure and success: DF DFX

• Provide methods of how to measure the quality of implementation for chosen DFXo Create a simple questionnaire about chosen DFXo Survey people w/ and w/o DFX lesson supporto Compare and use results to indicate where your

lesson is strong and weak

• Using this presentation as a template ensure your DFX contains all ingredients necessary to create a well-rounded lesson



Real World Examples: Slide Goals

• These are short examples that can give the user a quick example of how a particular DFX is used in daily life.

• Very high level and simple.

• Cite sources and link references where possible.

• Goal is to to ground the audience with examples that capture the DFX based on the discussion in the lesson to this point.

Real World Examples: Examples

• GOODo DF Customization: “vintage PC’s required the user to

manually install software drivers and alter BIOS settings when installing different hard drives, video cards, etc.”

Real World Examples: Examples

• POOR ExampleSuppose a worker must assemble a device that has two push-buttons

and a spring under each button.Sometimes a worker will forget a spring.A simple poka-yoke device was developed to eliminate this problem:

• The worker counts out two springs from a bin and places them in a small dish

• After assembly is complete, if a spring remains in the dish, the operator knows an error has occurred

HOWEVER: The operator has no way of knowing if one of the springs fell out of the dish, if both springs were put into the same button, the springs were put into the buttons correctly and then one of them fell out en route to being installed. The best way to poke yoke this would be to have the push-button molded around the spring to ensure presence at all times (this process is also easily poka yoke’d)

Taxonomy of DFX template 4

DF DFX Example

DF DFX ExampleSource: Guide to Course Design

INITIAL DESIGN PHASE: Build Strong Primary Components

Step 1. Identify important situational factors

Step 2. Identify important learning goals

Step 3. Formulate appropriate feedback and assessment procedures

Step 4. Select effective teaching/learning activities

Step 5. Make sure the primary components are integrated

INTERMEDIATE DESIGN PHASE: Assemble the Components into a Coherent Whole

Step 6. Create a thematic structure for the course

Step 7. Select or create an instructional strategy

Step 8. Integrate the course structure and the instructional strategy to

create an overall scheme of learning activities

FINAL DESIGN PHASE: Finish Important Remaining Tasks

Step 9. Develop the grading system

Step 10. De-Bug possible problems

Step 11. Write the course syllabus

Step 12. Plan an evaluation of the course and of your teaching3



Why You Care: Slide Goals

• Why do you need this part of the presentation?o To ensure the information being presented reaches

out to the target audience.

• What value does it add?o To have the target audience walk away with the

gained knowledge and be able to apply principles from the DFX reviewed obtain additional reference material.

• What should it accomplish in driving home the lesson of your chosen DF DFX?o The knowledge and skill sets presented are gained

and can be applied.

Why You Care: Examples

• Goodo Why does it matter to you?

All the work placed in creating the DFX should not be wasted. Knowledge placed in presentation should be shared, learned, and expanded upon.

• Pooro Why does it matter to you?

The presentation material doesn’t mesh well and target audience doesn’t gain the knowledge potential from the material.

Why Your Customers Care about DF DFX?

• Why does it matter to your customer?o When using the DFX your customer may notice part

variation, a squeak or rattle, a water or wind leak, a major component failure. These are some of the issues you must address when designing for the X.

o When using DFX the assembly plant will also be

affected. If a part is designed in a way in which it could be incorrectly built or very difficult to build.

Why Your Stakeholders Careabout DF DFX?

• Why does it matter to other stakeholders?o The stakeholders must be addressed in the DFX.

There are many stakeholders in that are affected by the design. Suppliers, service, end customer, management, testing etc.

o Keep the stakeholders in mind to manage their influence in relation to the requirements to ensure a successful project.



How to apply DFX: Slide Goals

• The reader should now have all the necessary background for how to apply the X. To further explain how to design for the X, you should detail the step by step process of how you, the expert, designs for the X.

How to apply DFX: Examples

• GOODo Each step of the DFX process is defined in understandable terms.o The reader can easily follow the process. o The process is not missing any steps.o The process is in a logical order.

• POORo The DFX contains no process of how to design for the X.o After reading the process the reader can not properly complete a

design using the DFX process.

How to apply DF DFX

• The DFX should-guidelines should be flexible and be adaptable to changing situations

• DFX - guidelines should be aware of the dependencies between contradicting DFXs

• DFX - guidelines should support the early and all of the development phases

• DFX - guidelines should include steps to review all related DFX and if possible work together in parallel

• DFX - guidelines should include any definitions that the average student would not know

• DFX - guidelines should look at impacts to stakeholders

• DFX process should be well defined, complete and not missing steps

• After reading this DFX the reader should be able to follow the guidelines to create a DFX of their own

How to apply DF DFX

Where possible, the DFX should follow a consistent general outline for better reading consumption by the end users reading multiple DFX’s. Here’s a recommended outline:

• Define The X• Define the Design for X• Define how you Design for X• Measuring DFX Failure and Success• Simple Real World Examples• Why you Care• How to Apply DFX• Key DFX Considerations• Case Studies



Key Considerations: Slide Goals

• The key considerations element of your DFX lesson is an opportunity to recapture highlights of the entire lesson. Highlighting pieces of information you want everyone to walk away with after reading your lecture.

• Focus on simple and easy examples that any user can implement nearly immediately in the real world with your DFX in mind.

• Link to other DFX’s that are relevant to your chosen DFX. Most of the DFX’s relate to each other in some aspect or another. It is important to highlight this DFX to other DFX’s and discuss how they work together.

• Reiterate the importance of stakeholders relationship with the DFX. Arguably one of the most important considerations with all DFX’s is how they relate to all of the relevant stakeholders.

Key Considerations: Examples

• Goodo DF HV Battery Sizing: Recap key points for DF HV

Battery for temperature control as it relates to other DFX’s

• Pooro Recap not presento Considerations don’t refer back to previously

mentioned material (first time information is mentioned)

o No discussion of how different stakeholders are affected

Key DF DFX Considerations

• Consider the applicability of other DFX subject matter to your topic. With this you take advantage of other existing resources to help educate your audience on your topic.

• The ability of the audience to understand the content is the prime consideration. If the intent of the lesson is unclear to them, then the content needs to be revised.

• NO PROPRIETARY INFORMATION

DF DFX Relation to other DFX’s

• DF Cohorts: DFX is an elective in the MPD program understanding how designing for DFX should fall within the scope of what makes good DF Cohorts.

• DF Product Evolution: Design the DFX lesson with the understanding that future classes will review, learn, update, and expand

• DF Testability: Good DF DFX is measurable and has the ability to self check itself to ensure the user is digesting the material



Case Study: Slide Goals

● Case studies are in depth examples of the application of particular DFX in practice

● The goal is to deep dive and explain in detail how a DFX was taken into consideration when generating a concept or design

● Case studies will pull together the ingredients demonstrated through the first part of the lesson and mix them together into a complete meal for the reader to consume

● Case studies can be actual examples from industry, projects conducted in other coursework, or exposes on what should have been done

● Case Background and History ○ Summary and scope of what the case study is and

necessary context to demonstrate DFX to given example

● What is the problem?○ Highlight the primary issue in the case and how DFX

could be applied to rectify the situation or improve the product

● Strength/Weakness of Case○ What are the pros/cons of the given system

Case Study: General Outline

● Key DFX Considerations and attributes○ Prior to application of DFX highlight needs and features that

are in need of DFX. What are signs that DFX is needed to improve

● How your DFX was implemented○ Using pieces from the original explanation and breakdown of

DFX walk through examples and steps of how the DFX was implemented to improve the process

● Key take aways for your DFX○ What have you learned and what can the user take away from

this study to help apply the given DFX in their lives

Case Study: General Outline

DF DFX Case Study: DFA5-Poka Yoke Background and History

• Design for Assembly (Part 5); DFA5: Poka Yoke is being chosen for our case because it stood out as one that could be shown to benefit from following DF DFX guidelines.

• Link to original DFX Lesson

https://docs.google.com/presentation/d/1pNh5oXVV_-m6tiLhaZDmGYfzFXQ4S-hngzSzMBK-m_k/edit

DF DFX Case Study: DFA5-Poka Yoke Problem Statement

• The Design for Assembly Part 5 (DFA5); Poka Yoke didn’t follow the original outline in slide #2. Also, when this file is read as a stand alone file (apart from the other DFA’s) it felt disconnected.

• The original slide #3 defines the term as Poka-Yoke, and majority of the slides refer to it as “Poke Yoke”. Consistency is important.

• A simpler DFX that shows the benefits of DF DFX.

DF DFX Case Study: DFA5-Poka Yoke Strengths and Weaknesses

• Strengthso Excellent examples with verbiage and imagery that

drive home the meaning and implementation of Poka Yoke

o Well thought out methodology

• Weaknesseso Limited scope and introduction to actual DFXo Outside of examples lack of guidelines of how to

apply DFX to other concepts or projectso No references for more indepth study should it be

desired

DF DFX Case Study: DFA5-Poka Yoke Implementation of DF DFX

• The following slides with light blue background are the DF Poka Yoke reimagined per the DF DFX breakdown at the beginning of the lesson.

• As you proceed, take note at how each piece of the lesson captures the goals described in the noted DF DFX architecture.

DEFINE: Poka Yoke

• Poka-yoke (poh-kah yoh-keh) means ‘mistake-proofing’ or more literally: avoiding (yokeru) inadvertent errors (poka). Ideally, poka-yokes ensure that proper conditions exist before actually executing a process step, preventing defects from occurring in the first place. Where this is not possible, poka-yokes perform a detective function, eliminating defects in the process as early as possible.2

Define the Design for Poka Yoke

The basic approach to design for Poka-Yoke should follow the

following guidelines:

1. The method should be Inexpensive

2. The method must be based on common sense and very obvious

to the person involved in the assembly process

3. The design must eliminate the ability for the error to occur.

Define how you Design for Poka Yoke

Step by Step process in applying Poka-Yoke:

1. Identify the operation or process - based on a pareto.2. Analyze and understand the way a process can fail.3. Decide the right poka-yoke approach, such as using a shutout

type (preventing an error being made), or an attention type (highlighting that an error has been made) poka-yoke take a more comprehensive approach instead of merely thinking of poka-yokes as limit switches, or automatic shutoffs a poka-yoke can be electrical, mechanical, procedural, visual, human or any other form that prevents incorrect execution of a process step.2

Define how you Design for Poka Yoke

Step by Step process in applying Poka-Yoke (continued):

4. Determine whether a: Contact - use of shape, size or other physical attributes for

detection. Constant number - error triggered if a certain number of \

actions are not made. Sequence method - use of a checklist to ensure completing

all process steps is appropriate.5. Trial the method and see if it works.6. Train the operator, review performance and measure success.2

Measuring DF Poka Yoke Failure and Success

• Successo The Poka Yoke feature prevents the assembly line

operator from installing the wiring in the wrong connector because the connectors shape does not allow it to be installed in the incorrect position.

• Failureo The Poka Yoke device does not prevent the improper

connection of the wiring harness’

Real World Examples of Poka Yoke

• Driver Dual-Stage Airbag Connector Interfaceo Connectors are “Keyed” and “Color-Coded” to

prevent incorrect assembly of the connectors.

Driver Airbag Clockspring - Airbag Connector Pigtails

Real World Examples of Poka Yoke

• The window in the envelope is not only a labor saving device, but it also prevents the contents of an envelope intended for one person being inserted in an envelope addressed to another individual

Envelopes

Why You Care about Poka Yoke

● You○ Improves quality, cost and performs a detective

function, eliminating defects in the process as early as possible

● Customer ○ Ensures satisfaction through delivering a high quality

product that works correctly and problem free out of the box (and ideally for duration of expected life)

● Other Stakeholders ○ Consistently correctly assembled products translates

to “Money money money!”

How can you Apply Poka Yoke

● Poka-yoke can be used wherever something can go wrong or an error can be made. It is a technique, a tool that can be applied to any type of process be it in manufacturing or the service industry.

● Errors are many types (6 listed):1. Processing errors

Make sure that welds/fasteners are accessible for detection equipment to verify their location/existance.

2. Setup errorUsing the wrong tooling or setting machine adjustments incorrectly.2

How can you Apply Poka Yoke

● Errors are many types (6 listed - continued):3. Missing part

Not all parts included in the assembly, welding, or other processes.

4. Improper part/itemWrong part used in the process.

5. Operations errorCarrying out an operation incorrectly; having the incorrect version of the specification.

6. Measurement errorErrors in machine adjustment, test measurement or dimensions of a part coming in from a supplier.2

Poka Yoke Key Considerations

● Poka Yoke requires immersion into the entire assembly process○ Assemblers will find a way to defeat the poka yoke○ Immersion allows for an understanding of the entire

assembly process and potential escape paths for defeating poka yoke

● Don’t assume misassembly only means not put together properly. What are other escape paths that could lead to a poor customer experience because of lack of poka yoke

Poka Yoke as it applies to other DFX

● DF Quality: DF Poka Yoke has become an industry standard in ensuring products achieve top quality and are consistently built as expected

● DF Testability: Good DF testability needs DF Poka Yoke to make sure tests cannot easily be fooled or “cheated.”

● DF Product Evolution: When designing a product for today as well as tomorrow it is important to understand how DF Poka Yoke may affect future iterations of a product.

DF Poka Yoke Case Studies

In effort to prevent a recursive loop of dfx-ness please refer to the original DF Poka Yoke for some excellent case studies

Link to original DFX Lesson

https://docs.google.com/presentation/d/1pNh5oXVV_-m6tiLhaZDmGYfzFXQ4S-hngzSzMBK-m_k/edit

DF DFX Case Study: DFA5-Poka Yoke Key DF DFX Take aways

Team how do you feel about how we applied DF DFX to DF Poka Yoke?

The intent of DF DFX, is to present the material in a clear and effective way. It is to help guide the author of the chosen DFX to reach the maximum potential of reaching out to even a novice reader by providing good detailed examples for the reader to take in and be able to apply to the DFX.

Reflect on the process

Drew

- Developing a template/process for creating a DFX was more complex than I imagined it would be. Trying to develop a format that allows the reader to absorb the content being presented was the most challenging since the flow needed to be logical and systematic. The existing DFX’s are in need of a major overhaul since most of the information presented in them is out of context with the actual DFX (it’s not really a DFX, it is just randomly presented information). This template will allow future revisions to the existing DFX’s and future DFX’s to be more readable and informative.

John

- From Part I of the DFX assignment, there are many DFX applications and the approaches taken to each of the DFX’s varied between them. This made reading the material harder to take in and some of the DFX’s varied in the way the material was also being presented. Working on our project to make improvements turned out to be more work than anticipated, but it was a great concept and the team met often to develop and achieve the goals. Hopefully, the DF DFX can become a benefit to future DFX overhaulers / authors.

Reflect on the process

Geno

-After working on the generic DFX outline I found it is very difficult to incorporate all the DFX into one outline. I feel we did a successful job at putting together a generic DFX that can be used by future classes. This project will enable the DFX material to be uniform and easier to understand.

Mark

-Reviewing the DFX coursework it became clear that i had a lot of examples and a lot of information for what many different types of DFX were. However, I found myself lost when it came to understanding how to apply any of these DFX’s. The purpose of any course is to absorb information for some sort of application. Therefore while deep diving and breaking down what DF DFX should be it became evident that the goal would be determining how to best aid absorption and ensure that absorption could be transferred into direct application.

References1 http://en.wikipedia.org/wiki/Design_for_X

2http://thequalityportal.com/pokayoke.htm

3 http://www.deefinkandassociates.com/GuidetoCourseDesignAug05.pdf

4 http://rd.springer.com/book/10.1007%2F978-3-642-30817-8

http://www.amazon.com/Creating-Significant-Learning-Experiences-Integrated/dp/0787960551

http://www.huffingtonpost.com/karl-gude/how-to-give-the-best-pres_b_3932280.html

http://www.forbes.com/2009/10/08/presentation-steve-jobs-technology-meetings-09-tips.html

http://hbr.org/2013/06/how-to-give-a-killer-presentation/ar/1

http://ocw.mit.edu/courses/#engineering-systems-division


http://math.coe.uga.edu/TME/Issues/v03n2/Eggleton.pdf

https://www.youtube.com/watch?v=AT9ho2G0N_Y

http://www.dtic.mil/ndia/2011system/13166_WillisWednesday.pdf

http://nptel.ac.in/courses/112101005/downloads/Module_5_Lecture_3_final.pdf

Ulrich K. T. and Eppinger St. D. Product Design and Development. McGrawHill Boston 2000

http://en.wikipedia.org/wiki/Design_for_X

http://thequalityportal.com/pokayoke.htm

http://www.deefinkandassociates.com/GuidetoCourseDesignAug05.pdf

http://rd.springer.com/book/10.1007/978-3-642-30817-8


http://www.huffingtonpost.com/karl-gude/how-to-give-the-best-pres_b_3932280.html

http://www.forbes.com/2009/10/08/presentation-steve-jobs-technology-meetings-09-tips.html

http://hbr.org/2013/06/how-to-give-a-killer-presentation/ar/1

http://ocw.mit.edu/courses/#engineering-systems-division



http://math.coe.uga.edu/TME/Issues/v03n2/Eggleton.pdf

https://www.youtube.com/watch?v=AT9ho2G0N_Y

http://www.dtic.mil/ndia/2011system/13166_WillisWednesday.pdf

http://nptel.ac.in/courses/112101005/downloads/Module_5_Lecture_3_final.pdf

Documents

Design for DFX April 15, 2015 Mark RockwellGeno Scalcucci John MurphyDrew Kamerzell A guide to creating effective documentation for all DFX’s