A product design framework for one-of-a-kind production using integrated quality function deployment and operational research techniques

The process of product design as an early stage of new product development provides systematic approaches that can lead to the success of a company’s competitive strategy in the current turbulent market. By launching an efficient product design procedure can result in the reduction of engineering modifications, cost and production time. One-of-a-Kind Product (OKP) is known as a particular manufacturing system of new product design and development with emphasis on the special order concept. Quality Function Deployment (QFD) is a comprehensive design framework with cross-functional team members that leads to the development of new or improved products. QFD starts with the House of Quality (HOQ) as an organizing matrix to identify the customers’ requirements (CRs) and translate them into the technical attributes (TAs) of the product and followed by determining the target values for the sets of technical attributes. An evaluation approach to determine the relative importance of CRs and TAs should be considered. In previous researches, the traditional methods such as simple scoring method and application of operational research techniques such as Analytic Hierarchy Process (AHP) were reported to weigh the requirements and attributes. Despite the obvious inner-relationships among the elements, considering the HOQ as a hierarchical system may be inefficient. In addition, the contradictory effects of a TA on two or more CRs, is the problem that has been neglected. Here, a mathematical model was developed for calculating the TAs target values. A case study (dry gas filter, Namdaran Petro-Gas Industries (NPI™)) is presented to exhibit and verify the procedure of OKP product design. Initially, the framework was developed by integrating QFD-operational research (Analytic Network Process (ANP)) as a systematic method for improvement of dry gas filter design. Interview and study of documents were used to identify the CRs. A robust evaluation on customers’ priority and attributes’ importance with respect to inner-relationships among criteria/sub-criteria was performed. Furthermore, the effects of TAs on CRs with regard to their direction (positive/negative) were considered as the fundamental for developing a Multi-Objective Decision Model (MODM) to be used for determining the TAs target values. For this purpose, the fuzzy conversion scaling technique followed by formulating the partial satisfaction separately was applied. Modified TOPSIS was used to select the basic design among the available designs for further modification. Later, the process continues with the second phase, translating the TAs into the key parts. The available options (retailers) to supply the key parts were identified. As the normal procedure of QFD the relative importance’s of key parts and the options were determined. Finally, a zero-one goal programming was presented to select the optimum options for each key part subject to the budget constraint. Overall, the developed QFD-ANP framework provides a systematic approach that has the potential to be used for designing OKP product

Manufacturing Quality Function Deployment: Literature Review and Future Trends

A comprehensive review of the Quality Function Deployment (QFD) literature is made using extensive survey as a methodology. The most important results of the study are: (i) QFD modelling and applications are one-sided; prioritisation of technical attributes only maximise customer satisfaction without considering cost incurred (ii) we are still missing considerable knowledge about neural networks for predicting improvement measures in customer satisfaction (iii) further exploration of the subsequent phases (process planning and production planning) of QFD is needed (iv) more decision support systems are needed to automate QFD (v) feedbacks from customers are not accounted for in current studies

Four Phases Quality Function Deployment (QFD) by Considering Kano Concept, TIME and Manufacturing Cost

Each company must carry out product development to maintain or build sales. Relationship between specifications and parameters of quality products to the wishes of the customer is an important consideration in doing product development. Product development methods QFD (Quality Function Deployment) has been widely applied in industry to maximize customer satisfaction based on quality, cost, time and other, become source of constraints. Quality, time and cost are important factors for a company to maintain existency of the company in the industry. This study will provide customer deployment requirements to consider not only the quality factors are more often a point of view assuming the successful development of a product, but also on the factors of time and cost. Factors to be considered in stages creating new products or improving old products are not only detailed data about the four phases of phasing as product planning, product design, process planning, process control and planning is needed, but also a complete view of the overall technical response . The final integration of the four phases of QFD is influential in producing and marketing the products. Team of product development must plan how to design new products to exploit existing technical response. Matters relating to the quality characteristic and the voice of stakeholders is very relevant and should be well understood and thoroughly. Technical approach to a more detailed response can lead a team of product developers to pay attention to the changes of each phase to obtain the allocation of resources for each of the responses are perfectly

Analysis of the agility of the automotive industry supply chain in times of COVID-19: a case study

In the early stages of the corona virus pandemic, business environment was changing rapidly. The Moroccan automotive industry was one of the export sectors most affected negatively by the corona crisis; it collapsed during the three months of confinement and the pandemic has created immense uncertainties in demand and disrupted global supply chains. Indeed, to save the automotive industry, Morocco relies on its competitiveness and challenges current supply models for supply chain agility in order to better prepare for future disruptions. Achieving a competitive edge requires aligning company with suppliers and customers as well as working together to achieve agility, organizationally, strategically and individually. However, agile supply chains are the most powerful competitive vehicles of the manufacturing companies. To help automakers deal with the many challenges associated with the pandemic, let’s present this research on the key enablers that will need to be monitored as the situation evolves. Thus, our article presents an original approach which, by linking the competitive priorities, agile supply chain attributes and enablers, aims at evaluates and enhances supply chain agility of a Moroccan automotive factory. Let’s adopt fuzzy quality function deployment (FQFD) approach and, in particular, the two houses of quality (HOQ) with a fuzzy scale in order to identify the most appropriate enablers to be implemented by the factory. This evaluation demonstrates that there are three enablers needing maximum attention: process compliance, logistics and distribution capabilities and supportive information technology. Then, the supply chain agility improvement should be based on these enabler

Review on recent advances in information mining from big consumer opinion data for product design

In this paper, based on more than ten years' studies on this dedicated research thrust, a comprehensive review concerning information mining from big consumer opinion data in order to assist product design is presented. First, the research background and the essential terminologies regarding online consumer opinion data are introduced. Next, studies concerning information extraction and information utilization of big consumer opinion data for product design are reviewed. Studies on information extraction of big consumer opinion data are explained from various perspectives, including data acquisition, opinion target recognition, feature identification and sentiment analysis, opinion summarization and sampling, etc. Reviews on information utilization of big consumer opinion data for product design are explored in terms of how to extract critical customer needs from big consumer opinion data, how to connect the voice of the customers with product design, how to make effective comparisons and reasonable ranking on similar products, how to identify ever-evolving customer concerns efficiently, and so on. Furthermore, significant and practical aspects of research trends are highlighted for future studies. This survey will facilitate researchers and practitioners to understand the latest development of relevant studies and applications centered on how big consumer opinion data can be processed, analyzed, and exploited in aiding product design

A fuzzy front end model for concurrent specification in new product development

This research reports on the development of a new model for an early design stage in new product development (NPD) programmes called the Fuzzy Front End (FFE). The new FFE model aims at overcoming two kinds of limitations identified in previous FFE models. The first limitation concerns current trends in FFE model improvement including the need for a data-driven model, and to address agile development, incremental and radical NPDs, balanced explicitness and responsiveness characteristics, and balanced procedural and performative structures. The second limitation concerns deficiencies in the performance structure and operating mechanism regarding contextual performance and concurrent collaboration. This means that performances in the FFE do not systematically link with each other, either in a single functional domain or multidimensionally across diverse functional domains, but instead exist independently. A pragmatic-prescriptive model has been functionally embodied by analysing real-world FFE scenarios using inductive reasoning. The model is data-driven with a performative structure wherein parameters can interlock for contextual performance and concurrent collaboration throughout the entire FFE process. With this interlocking structure, once an initial parameter is produced, all remaining parameters considered from both perspectives can be obtained successively. This model allows performers to explicitly understand the purpose and roles of parameters and their relationships from both perspectives when processing parameters. The model thus leads to more agile FFE execution by reducing the iterative work needed to correct defective parameters which have not been handled with contextual performance and concurrent collaboration in mind but instead exist independently. A theoretical-descriptive model, produced by validating the developed pragmatic-prescriptive model, using deductive reasoning, consists of mathematical formulas, providing the underlying concept of an overall FFE as well as that of its parts. Consequently, the pragmatic-prescriptive model can serve as functional performance guidance, while the theoretical-descriptive model can serve as conceptual performance guidance when employing the pragmatic-prescriptive model.Open Acces

Research on cost management methods used in new product development and their relationship to strategic priorities and collaborative competences: A systematic literature review and survey of the German manufacturing industry

This doctoral thesis presents a systematic review in both the management accounting as well as the innovation and operation management literature on 15 different methods for cost management. Subsequently, six antecedents of the adoption of cost management methods are identified and empirically analysed. It was found that the antecedents explaining the adoption of this methods during NPD are cost leadership

Critical appraisal of product development expertise in Irish SMEs

The focus of this research was on the product development expertise of Irish SMEs. In particular, SMEs developing physical products (a physical product is defined as an electronic, medical device, plastic or general engineering product). A survey of Irish SMEs was conducted across industry sectors developing physical products with the objective of understanding how indigenous SMEs and therefore Ireland is progressing towards becoming a knowledge economy. SME characteristics (customers and markets, organisational structures, systems, processes and procedures, human and financial resources, culture and behaviour) were researched and used to understand the issues SMEs have with product development (PD research is mostly considered from the perspective of large companies). In relation to product development: strategy, innovation and learning, strategic techniques, organisational structure, product development process design, types of product development processes, tools and methodologies, technology, intellectual property, change management, marketing and branding and performance measurement were all examined. Survey items (variables) were identified from the literature review and used to create a survey designed based on ‘best practice’ PD and SME characteristics. This survey was conducted based on identified survey best practice in order to increase response rate and went through two pre-tests and a pilot before the final study. Descriptive analysis, reliability/consistency analysis and regression analysis were conducted on the constructs of product development. Specific relationships identified in the literature review were examined. The results of this analysis revealed that Irish SMEs are operating in a ‘Knowledge Based Development’ or learning environment. They carry out many of the techniques associated with various tools and methodologies but reported no use of these T&M which could aid their approach. There is a high use of technology, especially CAD and technology is mostly developed within the product development process. There was a high use of Cross Functional Teams and in general strategy and fuzzy front end/voice of the customer usage was carried out well. There were no issues with change management and in relation to intellectual property the use of an IP policy, strategy and portfolios was low. Generally, Irish SMEs are ready to reach the next stage of company evolution by linking ‘organisational (innovation) processes’

Some further studies on improving QFD methodology and analysis

Quality Function Deployment (QFD) starts and ends with the customer. In other words, how it ends may depend largely on how it starts. Any QFD practitioners will start with collecting the voice of the customer that reflects customer’s needs as to make sure that the products will eventually sell or the service may satisfy the customer. On the basis of those needs, a product or service creation process is initiated. It always takes a certain period of time for the product or service to be ready for the customer. The question here is whether those customer-needs may remain exactly the same during the product or service creation process. The answer would be very likely to be a ‘no’, especially in today’s rapidly changing environment due to increased competition and globalization. The focus of this thesis is placed on dealing with the change of relative importance of the customer’s needs during product or service creation process. In other words, the assumption is that there is no new need discovered along the time or an old one becomes outdated; only the relative importance change of the existing needs is dealt with. Considering the latest development of QFD research, especially the increasingly extensive use of Analytic Hierarchy Process (AHP) in QFD, this thesis aims to enhance the current QFD methodology and analysis, with respect to the change during product or service creation process, as to continually meet or exceed the needs of the customer. The entire research works are divided into three main parts, namely, the further use of AHP in QFD, the incorporation of AHP-based priorities’ dynamics in QFD, and decision making analysis with respect to the dynamics. The first part focuses on the question "In what ways does AHP, considering its strength and weakness, contribute to an improved QFD analysis?" The usefulness of AHP in QFD is demonstrated through a case study in improving higher education quality of an education institution. Furthermore, a generalized model of using AHP in QFD is also proposed. The generalized model not only provides an alternative way to construct the house of quality (HoQ), but also creates the possibility to include other relevant factors into QFD analysis, such as new product development risks. The second part addresses the question "How to use the AHP in QFD in dealing with the dynamics of priorities?" A novel quantitative method to model the dynamics of AHP-based priorities in the HoQ is proposed. The method is simple and time-efficient. It is especially useful when the historical data is limited, which is the case in a highly dynamic environment. As to further improve QFD analysis, the modeling method is applied into two areas. The first area is to enhance the use of Kano’s model in QFD by considering its dynamics. It not only extends the use of Kano’s model in QFD, but also advances the academic literature on modeling the life cycle of quality attributes quantitatively. The second area is to enhance the benchmarking part of QFD by including the dynamics of competitors’ performance in addition to the dynamics of customer’s needs. The third part deals with the question "How to make decision in a QFD analysis with respect to the dynamics in the house of quality?" Two decision making approaches are proposed to prioritize and/or optimize the technical attributes with respect to the modeling results. Considering the fact that almost all QFD translation process employs the relationship matrix, a guideline for QFD practitioners to decide whether the relationship matrix should be normalized is developed. Furthermore, a practical implication of the research work towards the possible use of QFD in helping a company develop more innovative products is also discussed. In brief, the main contribution of this thesis is in providing some novel methods and/or approaches to enhance the QFD’s use with respect to the change during product or service creation process. For scientific community, this means that the existing QFD research has been considerably improved, especially with the use of AHP in QFD. For engineering practice, a better way of doing QFD analysis, as a customer-driven engineering design tool, has been proposed. It is hoped that the research work may provide a first step into a better customer-driven product or service design process, and eventually increase the possibility to create more innovative and competitive products or services over time