Improvement to quality function deployment methodology : a thesis presented in partial fulfilment of the requirements for the degree of Doctor of Philosophy in Applied Statistics at Massey University, Palmerston North, New Zealand

Content removed from thesis due to copyright restrictions: Iqbal, Z., Grigg, N. P., Govindaraju, K., & Campbell-Allen, N. M. (2016). A distance-based methodology for increased extraction of information from the roof matrices in QFD studies. International Journal of Production Research, 54(11), 3277-3293. doi:10.1080/00207543.2015.1094585 Iqbal, Z., Grigg, N. P., & Govindaraju. (2017). Performing competitive analysis in QFD studies using multipole moments and bootstrap sampling. Quality Engineering, 29(2), 311-321. doi:10.1080/08982112.2016.1181181 Iqbal, Z., Grigg, N. P., Govindaraju, K., & Campbell-Allen, N. (2014). Statistical comparison of final weight scores in quality function deployment (QFD) studies. International Journal of Quality & Reliability Management, 31(2), 184-204. doi:10.1108/IJQRM-06-2013-0092 Iqbal, Z., Grigg, N. P., Govindaraju, K., & Campbell-Allen, N. M. (2015). Enhancing prioritisation of technical attributes in quality function deployment, 64(3), 398-415. doi.10.1108/IJPPM-10-2014-0156Quality Function Deployment (QFD) is a quality improvement methodology which translates true customer requirements into technical solutions. The major purposes in implementing QFD are enhancing quality, decreasing production cycle time, and lowering costs. QFD methodology utilises a system of matrix like structures known as the House of Quality (HOQ) which work collectively to determine final weightings of the technical characteristics. The derivation of final weights of the technical characteristics and their prioritisation is the final key in QFD process. One of the main theoretical difficulties in employing QFD is that it deals with multidimensional categorical (ordinal) data variables. The rating data of these categorical variables varies from person to person and case study to case study. In prioritising the technical characteristics, QFD practitioners often fail to fully integrate the diverse information extractable from ordinal data and ignore some sections of QFD, House of Quality (HOQ). It is also observed that in each matrix of QFD-HOQ, numerous heuristics have been introduced to suppress the variation, uncertainty and vagueness. During the QFD process, any mistakes such as selection and interpretation of rating scales, application of methods, or integration of various matrices can fail the whole process. In this project with the rationale to improve QFD methodology, a systematic emphasis is placed on the following issues i) Application of methods, procedures, techniques for the appropriate selection of likert scales within each matrix of QFD-HOQ. ii) Application to each matrix, data and their integration towards statistically valid conclusions. iii) Close observation and interpretation of the final prioritisation of technical characteristics (TCs), and its enhancement

PERANCANGAN JIG MAIN STEAM DI PT. TOMOE VALVE BATAM

Tomoe Valve Batam is a Manufacturing of Butterfly Valve, Accuator and Accessories. manufacture. PT. Tomoe Valve Batam has difficulty in fulfilling order orders because the Main Steam product setting process is too long so the production capacity is low, so it is necessary to design a Jig in the Main Steam product setting process in order to eliminate the processing time setting. This research was conducted at the production division using the Quality Function Deployment analysis method. The stages in this study use Voice of Costumer which is useful to find out the company's interests, product attributes and technical responses in order to eliminate the long set up time so that production capacity is reached. After that stage is completed, an analysis is conducted using the QFD method. Identify the quality deployment function (QFD) as one of the tools that can be used to identify customer needs and link the needs to product design. PT. Tomoe Valve Batam was success to cut off settiing time with QFD method to increasing production output

PERANCANGAN PRODUK JEMURAN PAKAIAN PORTABLE DENGAN MENGGUNAKAN QUALITY FUNCTION DEPLOYMENT

Designing portable clothesline products to meet customer needs using the Quality Function Deployment Method. This research was conducted in the city of Batam where a small city, very densely populated, with the majority of the population are company workers. Drying is a tiring job, and therefore effective, efficient drying is needed to make it easier for users to carry and store. The use of the Quality Function Deployment method goes through 4 phases of the process namely House of Quality (HOQ), design Deployment, manufacturing planing, Product Planing , by taking a sample of 122 respondents from three housing estates namely Puriagung, Genta Batuaji, and Villa Mukakuning. This study uses a validity and reliability analysis test using a significance level of 0.05 with 122 respondents from the results of r table 0.1779 declared valid, then reliability testing using cronbach alpha values ​​0.6, 60% with the results of 0.980, 0.968 and 0.760. from passing 4 phases in QFD produces portable clothesline with a total of 24 hook hangers, clothesline that can be folded on its side, and clothesline that can be set high and low. The attributes developed are based on certain considerations and the results of the respondent's questionnaire

New Product Development Strategy for Sustainable Rigid Plastic Packaging at XYZ Company in 2022-2025

This study developed environmentally friendly products for XYZ Company through business strategy analysis, macro external environment analysis, industry analysis, the voice of customer analysis, functional analysis, canoe model integration and quality functional deployment, and cost-benefit analysis. Based on the analysis results, a new product development strategy for sustainable rigid plastic packaging was formulated at XYZ Company in 2022-2025. The formulation of a new product development strategy at XYZ Company began by collecting data from XYZ Company's Business Strategy, analyzing internal factors using functional analysis, and analyzing the external environment (regulations, economic, social, political conditions, industry pressures, and results of customer interviews with XYZ Company) with using PESTEL Analysis, Industry Analysis (Five Forces Porter), and Voice of Customer Analysis. All data were combined in the Kano model matrix and Quality Function Deployment Matrix, which produced new product characteristics that will become the basis for XYZ Company in designing new products, conducting cost and benefit analysis, and determining strategy formulation. Based on the analysis results, XYZ Company could develop a 20L Jerrycan product for refillable packaging with Post-Consumer Resin (PCR) Material, using Extrusion Blow Molding and Injection Molding Process, and collaborating with customers to develop product cycles for refillable packaging offered to customers. The XYZ Company's effective New Product Development Strategy for sustainable plastic packaging in 2022-2025 is manufacturing refillable packaging with PCR material and using existing machines. Keywords: product development, kano model, quality functional deployment, sustainability, rigid plastic packagin

PERANCANGAN MESIN POTONG AKRILIK YANG ERGONOMIS DAN EKONOMIS MENGGUNAKAN METODE ERGONOMIC FUNCTION DEPLOYMENT (EFD)

Advertising services which include the process of creating, producing and distributing advertisements, one example of which is billboards used to help entrepreneurs in promoting goods and services sold in Pekanbaru. In the process of working on advertising media, especially in the cutting process using cutting tools in the form of circular saws and scroll saws. In the cutting process there are several obstacles that are often experienced by operators, cutting edges are difficult to find, the unit is expensive, cutting edges often break, dynamo power can drop dramatically, work takes a long time and operators feel tired, that's why it is necessary to design an acrylic cutting machine which can be used to meet the operators needs at work. The design method uses the Ergonomic Function Deployment (EFD) method. This method is a development of the Quality Function Deployment (QFD) method. The stages in this research are introduction, identification, formulation, goal setting, method application followed by analysis and discussion, and finally conclusions, suggestions, and improvements. Based on the research, the variable results obtained from a closed questionnaire and processed using SPSS 16 software

Applying fuzzy analytic network process in quality function deployment model

In this paper, we propose an empirical study of QFD implementation when fuzzy numbers are used to handle the uncertainty associated with different components of the proposed model. We implement fuzzy analytical network to find the relative importance of various criteria and using fuzzy numbers we calculate the relative importance of these factors. The proposed model of this paper uses fuzzy matrix and house of quality to study the products development in QFD and also the second phase i.e. part deployment. In most researches, the primary objective is only on CRs to implement the quality function deployment and some other criteria such as production costs, manufacturing costs etc were disregarded. The results of using fuzzy analysis network process based on the QFD model in Daroupat packaging company to develop PVDC show that the most important indexes are being waterproof, resistant pill packages, and production cost. In addition, the PVDC coating is the most important index in terms of company experts’ point of view

ANALISIS KUALITAS JASA PELAYANAN TERHADAP KEPUASAN PELANGGAN DI DEALER MOTOR HONDA KEDIRI DENGAN METODE QUALITY FUNCTION DEPLOYMENT (QFD)

ABSTRAK Fokus utama dari QFD adalah melibatkan pelanggan pada proses pengembangan produk sedini mungkin. Tujuan dari QFD sendiri tidak hanya memenuhi sebanyak mungkin harapan-harapan pelanggan, tapi juga berusaha melampaui harapan pelanggan sebagai cara untuk berkompetisi, sehingga diharapkan konsumen tidak menolak dan tidak komplain tapi malah menginginkannya. Tujuan penelitian untuk mengetahui dan menganalisis kualitas jasa pelayanan di Dealer Motor Honda Kediri. Tujuan penelitian ini adalah untuk mengetahui dan menganalisis kepuasan pelanggan di Dealer Motor Honda Kediri dengan menggunakan metode QFD. Untuk menentukan apa yang harus dilakukan perusahaan untuk meningkatkan kepuasan pelanggan Jenis penelitian ini merupakan penelitian deskriptif kuantitatif. Jumlah sampel sebanyak 110 konsumen yang menjadi pelanggan Dealer Motor Honda di Kota Kediri. Teknik analisis menggunakan Quality Function Deployment (QFD). Hasil penelitian menunjukkan bahwa bahwa atribut Responsiveness memiliki kesenjangan yang terbesar (-0,96) dan atribut Assurance memiliki kesenjangan terkecil (-0,91). Upaya yang dapat dilakukan perusahaan untuk meningkatkan kepuasan pelanggan dapat dilakukan pada atribut Responsiveness perusahaan seharusnya memperhatikan kecepatan petugas bengkel dalam menyelesaikan masalah kepada pelanggan di Dealer Motor Honda Kediri. Saran penelitian ini sebaiknya perusahaan memperbaiki atribut Responsiveness yang terdiri dari kecepatan petugas bengkel dalam menyelesaikan masalah, tidak lama menunggu untuk dilayani petugas, serta responsif terhadap permintaan konsumen. Kata Kunci : Kualitas Jasa Layanan, Quality Function Deployment,  Pelanggan   ABSTRACT The main focus of QFD is to engage customers in the product development process as early as possible. The purpose of QFD themselves as much as possible not only meet customer expectations, but also to go beyond customer expectations as a way to compete, so expect consumers do not resist and did not complain but instead want it. The aim of research to determine and analyze the quality of services at the in Honda Dealer Motor Kediri. To know and analyze customer satisfaction in Kediri Honda Motor Dealer by using QFD. To determine what should be done by the company to improve customer satisfaction. This research is quantitative descriptive study. Total sample of 110 consumers who are customers in Honda Dealer Motor Kediri. Mechanical analysis using Quality Function Deployment (QFD). Results of attribute Responsiveness has the largest gap (-0.96) and attribute Assurance has the smallest gap (-0.91). Attempts to do the company to improve customer satisfaction can be performed on the attributes Responsiveness companies should pay attention to the speed mechanic in solving the problem to customers in Honda Dealer Motor Kediri. Keywords: Service Quality, Quality Function Deployment, Customer

IMPROVEMENT DESIGN OF COVER NUT PRODUCTION PROCESS USING LEAN MANUFACTURING APPROACH TO REDUCE REWORK ACTIVITIES

PT. NAGOYA is a company engaged in the rubber, polyvinyl chloride and plastic industry. PT. NAGOYA producing spare parts made from rubber for the needs of movable vehicles, such as seal switches, lever seals, safety regulators, seal buttons, R3, cover nuts, water reservoir tank caps, seal bracket, rubber discs, rubber dumper. Among all the products produced during the research, namely the seal switch, cover nut, seal bracket, and K3, the cover nut has the longest lead time, which is 71 minutes, there is a difference for 48 minutes with seal bracket, which is the most produced product. After further analysis, in the production process of cover nut, there is a reworked activity caused by waste defects in the cutting area. Cutting area has the highest defect value compared to other areas in the cover nut production process as much as 86.67%. The waste defect caused by an unsuitable result of cutting the compound. Efforts are being made to minimize waste defects and eliminate rework activities using lean manufacturing. Creating value stream mapping (VSM) and Process Activity Mapping (PAM) to map the flow of information and the flow of the production process. Next, identify the root of the waste defect using 5 whys. The problem of the waste defect will be solved by improving the design of cutting tools using the quality function deployment method and improving the system to the automatic using controller. After that, creating value stream mapping (VSM) current state and compared to value stream mapping (VSM) future state to find out the differences that occur after the implementation of the proposed design. The result obtained from the proposed design is stable cutting result caused by an automatic system so defects will be reduced and will eliminate rework activities in the cover nut production process at PT. NAGOYA so the production lead time will be reduced by 280,063 seconds or 8%.Keywords: lean manufacturing, quality function deployment method, waste defect, controller, rubbe

QFD analysis of RSRM aqueous cleaners

This paper presents a Quality Function Deployment (QFD) analysis of the final down-selected aqueous cleaners to be used on the Redesigned Solid Rocket Motor (RSRM) program. The new cleaner will replace solvent vapor degreasing. The RSRM Ozone Depleting Compound Elimination program is discontinuing the methyl chloroform vapor degreasing process and replacing it with a spray-in-air aqueous cleaning process. Previously, 15 cleaners were down-selected to two candidates by passing screening tests involving toxicity, flammability, cleaning efficiency, contaminant solubility, corrosion potential, cost, and bond strength. The two down-selected cleaners were further evaluated with more intensive testing and evaluated using QFD techniques to assess suitability for cleaning RSRM case and nozzle surfaces in preparation for adhesive bonding