Module8_DFMEA_Testing_Innovation_Creativity_v7Innovation_Creativity_v7Delivery_v1.pptx

Innovation_CreativityInnovation_Creativity_v7Innovation_Creativity_v7_v7

1. DFMEA : Design for Robustness Pick one project from your group for this section

2. DFMEA Steps Review the design Brainstorm potential failure modes List potential effects of failure List potential causes for each failure Rank failures Severity Occurrence Detection RPN = Severity X Occurrence X Detection Develop action plan Implement fixes Revisit potential failure risks

3. In a group, identify one project to use as an example for this exercise Describe the project so the whole group understands it

4. Brainstorm Failures What could go wrong? What could break? Are there systems your design relies upon? e.g. myEPICS authenticates through Purdue’s career accounts Are there things that could fail over time?

5. Brainstorm a list of potential failures and their causes for one project

6. Rate failures Rating (1 to 10) Severity How severe are the consequences to the failure Occurrence How often are the failures likely to occur? Detection How easily are the failures detected?

7. DFMEA Calculations Scores for Severity, Occurrence and Detection 1 to 10 1 = Low 10 = High Risk Priority Number (RPN) RPN =Severity X Occurrence X Detection

8. DFMEA Matrix Failure mode Effect of Failure Cause of failure Severity Occurrence Detection Rating

9. Take 5 potential failure scenarios and rate them

10. Example http://en.wikipedia.org/wiki/Failure_mode_and_effects_analysis , accessed 22 Aug. 2011

11. Example Chart

12. Identify the failure scenario that should be addressed first

13. Develop an action plan to address the failure scenario

14. Continue the process Implement the plan to eliminate the failure scenario Revisit other potential failure risks Prioritize Eliminate failure scenarios Continue until risks are below determined thresholds Show to the design reviews for confirmation

15. Can we get rid of all failures? All cars have brakes that will eventually fail Potentially catastrophic Early warning squealers to notify

16. Questions/Discussion

17. Testing in Design William Oakes

18. Learning Objectives At the end of this session, you will be able to: Describe at least three ways to test your projects Describe how prototypes can be used in testing Categorize potential failures for a design

19. Testing How do we know our projects will work ? When we deliver it? For the intended life? What is the expected life? How do we know the project will function like we want and for the users intended? How do we know we are meeting the right needs?

20. Testing Designers have to know that their design will function Plan testing along the way Tests look at Function – does it perform like we intended Under what conditions? User testing – does it meet needs Can people use it as intended

21. GE Jet Engines Test examples : Performance – did it produce enough thrust to fly the plane? Endurance – Will it last? Safety – is it safe?

22. Jet Engine Testing Proof of concept Analysis – computer tests Component tests Fit and form CAD models Wooden and/or rapid prototype models Can we reach things? Interface fits

23. Jet Engine Testing Assembly tests Ground tests Performance Endurance – simulate flights Safety – what could go wrong Bird strikes Water (rain) ingestion Hail ingestion Blade failures Flight tests

24. Other experiences Test in the proper conditions Refrigerators testing in an open room rather than against a wall Medical equipment Tested on range of people Food products Taste, preferences and buying habits

25. “Fail quickly and cheaply ” Prototyping….rough, quick, very interative IDEO working with Gyrus ACMI to design new apparatus for operating on delicate nasal tissues Prototype: http://cataligninnovation.blogspot.com/2008/11/prototyping-foundational-competency-of.html

26. Think, pair, share…. What questions and/or issues need to be tested for your current project? Find one or two others to share your answers Introduce yourself Describe your project Answer the first question

27. More discussion Individually What tests need to be done on the project? Share what you answered for your project with the same person or pair.

28. Test plans At GE and other companies there are teams that are dedicated on testing How do we take an engine and test it? How do we test a new medical device? How to we insure that the software works? Create a test plan for your design What tests need to be done? What will they measure? What are the criteria for success and failure?

29. Test Plans What will be tested Who and/or where will it be done What will be measured? Success or failure Test #1 Test #2 Test #3 Test #4 Clearly define what will be done and by whom

30. Sample Test Plan Template Test Plan Template.docx on Canvas 1 Description of Product 1.1 Components of interest 1.1.1 Dimensions 1.1.2 Photographs 1.2 Specific, important characteristics 1.2.1 Materials, tolerances, limitations 1.2.2 How close is this test vehicle to the expected final product 2 Objectives of Test 2.1 Overall goal (characterization, optimization, test to failure, e.g.) 2.2 Specific parameters to be measured 2.3 Target values of outputs 2.4 Test Success Criteria Definition 2.4.1 What new knowledge will you have gained 2.4.2 How will you use the new knowledge 2.4.3 Is the comfort/safety of humans interacting with the product compromised 2.5 Is a redesign required

31. Discussion In your pairs or groups, identify one test that was proposed and develop the who, what, where, why and the success criteria

32. Test tips User testing and prototypes Component tests Small parts that are demonstrated can help hold the team accountable Fit and form tests Simulate usage Walked on the Martian surface Use Cases – software Build a case or example of how to use the design and see if it works correctly

33. Another example… Testing in the proper conditions

34. Delivery of Projects

35. Delivery Steps Review the delivery checklist used at Purdue Modify the checklist assuming that your students will finish their designs and deliver them to a user or client

36. Questions/Discussion