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You are here: Home / Archives for Quality during Design

Quality during Design

Quality during Design is the place for product designers to use quality thinking throughout the design process to create products others love, for less.

by Dianna Deeney Leave a Comment

QDD 030 Using Failure Rate Functions to Drive Early Design Decisions

QDD 030 Using Failure Rate Functions to Drive Early Design Decisions

Using Failure Rate Functions to Drive Early Design Decisions

We have good requirements for the reliability of our design. We also have a preliminary design with ideas of how we’re going to manufacture it. Is our design idea good enough? Are there things we should do to improve its performance and reliability?

For a physical product, there are three general stages in its life cycle. In many cases the failure rates of physical products can be represented by a reliability bathtub curve. This curve is really a plot of a hazard rate function, also known as a failure rate function. We talk about data collection in the early design phase, what types of failures are typical for each phase, and design decisions we may make to improve our reliability, based on the failure rate function we plot for our system.

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 029 Types of Design Analyses possible with User Process Flowcharts

QDD 029 Types of Design Analyses possible with User Process Flowcharts

Types of Design Analyses possible with User Process Flowcharts

Flowcharting isn’t just useful for manufacturing processes. We can use them in lots of ways to help us with design of products and to identify quality characteristics. After all, products are used by people, and the way in which they use them is a process.

  • compare ideal vs. actual flowcharts
  • identify where there is disagreement about correct sequence or steps
  • identify common mistakes/problems at each step to mistake-proof the process and design
  • look for holds or delays, find the critical path

We also talk about specific flowchart analyses and how they can be used to analyze the user process for design.

  • Cost-of-Poor-Quality
  • Critical-to-Quality
  • Value-Added Analysis
  • Deployment Flowchart

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 028 Design Tolerances Based on Economics (Using the Taguchi Loss Function)

QDD 028 Design Tolerances Based on Economics (Using the Taguchi Loss Function)

Design Tolerances Based on Economics (Using the Taguchi Loss Function)

Defining tolerances for our quality characteristics is sometimes not an easy task. If we set tight tolerances, it could be costly to make with a lot of rejects and rework in the future. If we’re too sloppy with our tolerances, then it can affect the functionality of our product, leading to unhappy customers, and also possible rework and scrap. There’s economics involved in setting-up tolerances.

Genichi Taguchi related his measure of quality (variation from the target spec) with economics, called the Taguchi Loss Function. It’s used to calculate the cost (in money) of a certain deviation from a target value. It assumes that the farther our quality characteristic is from our target value, the more costly it is to us.

We talk about how we can use the Taguchi Loss Functions as a way for us to set tolerances for our designs. Scroll lower to get an interactive tool and the equations.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 027 How Many Controls do we Need to Reduce Risk?

QDD 027 How Many Controls do we Need to Reduce Risk?

How Many Controls do we Need to Reduce Risk?

When we’ve identified a risk to our design or user process – and that risk can pose a potential harm – how many controls do we need to add?

We discuss prevention vs. detection controls, ALARP, as low as possible, and some scenarios where we could (and maybe couldn’t) justify a risk as acceptable without adding additional controls.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 026 Solving Symptoms Instead of Causes?

QDD 026 Solving Symptoms Instead of Causes?

Solving Symptoms Instead of Causes?

How we describe and approach the issues we need to solve can affect how we react to them.  We know we’re supposed to be solving for root causes. But are we, instead, really just addressing symptoms? Are we celebrating the quick fix and then moving on without addressing the root of our issue?

“If you define the problem correctly, you almost have the solution.” – Steve Jobs

Recognize the common mishaps of us solving symptoms instead of really getting to the causes. And, clearly describe our problem in two parts (statement and description of facts) to be confident that we’re moving toward solving the causes.

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 025 Do you have SMART ACORN objectives?

QDD 025 Do you have SMART ACORN objectives?

Do you have SMART ACORN objectives?

Objectives are goalposts of what it is we’re trying to accomplish. Though they’re only a part of planning a project, if we don’t have well-defined and clear objectives, it could lead to us not having the stellar project results we want. Our objective should be a SMART ACORN.  We review these two, complementing acronyms as ways to check that we’re setting up our project for success.

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 024 Why Look to Standards

QDD 024 Why Look to Standards

Why Look to Standards

Standards are everywhere, and lots of organizations are sourcing and creating them. The U.S. Federal Trade Commission held a workshop 2019 that recently made the news, again, in July 2021. It was called “Nixing the Fix: a Workshop on Repair Restrictions”. Here’s what it’s about: manufacturers are not creating products with standard parts, or their design is created so its difficult for consumers to repair.

Are standards part of the answer? How can we proactively use them for design? Why should we?

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 023 Getting the Voice of the Customer

QDD 023 Getting the Voice of the Customer

Getting the Voice of the Customer

Before we can link customer needs to design, production, and service of our products, we need to listen to and understand the voice of the customer.  We review 6 common VOC collection strategies, and talk about their pros and cons. We also discuss an affinity diagram process, which may help our team organize all of the data to get to customer needs.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 022 The Way We Test Matters

QDD 022 The Way We Test Matters

The Way We Test Matters

We can look at test methods like a product in and of itself. Because tests also have requirements and need to produce usable results, we validate against those requirements. Validating our test method also ensures that they are precise and accurate.

We talk about things to consider when looking at product tests: tying test methods to the product’s use environment, standards, and cumulative effects of testing.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 021 Designing Specs for QA

QDD 021 Designing Specs for QA

Designing Specs for QA

Creating specs for suppliers and producers is generally at the forefront of our thoughts about the activity. But, it’s also important to design for our QA friends, too, for inspection.

We talk about what acceptance sampling is all about. We also step through a thought process for identifying and creating design features for inspection using FMEA.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 020 Every Failure is a Gift

QDD 020 Every Failure is a Gift

Every Failure is a Gift

When designs fail we can take on damaging mindsets while we’re deciding our next steps, and this can lead us to bad decisions. We explore this and give some examples of pitfalls. We also talk about what to do within the design-realm to prepare for and combat those mindsets. Finally, I share my mantra when designing activities get tough with failures.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 019 Understanding the Purposes behind Kaizen

QDD 019 Understanding the Purposes behind Kaizen

Understanding the Purposes behind Kaizen

In the quality world, kaizen is a tool for continuous improvement under the umbrella of a Lean philosophy. The quality-tool kaizen is just one layer of a larger, overarching idea that we benefit from small, incremental improvements made consistently.

Kaizen as a tool involves all employees of the company toward continuous improvement. The way kaizen events are done helps to promote the continuous improvement philosophy throughout the business through its effect on culture, time, proof, and teamwork. We talk more about how this all fits together in the podcast.

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 018 Fishbone Diagram: A Supertool to Understand Problems, Potential Solutions, and Goals

QDD 018 Fishbone Diagram: A Supertool to Understand Problems, Potential Solutions, and Goals

Fishbone Diagram: A Supertool to Understand Problems, Potential Solutions, and Goals

A Fishbone Diagram is named for its looks because it resembles the bones of a fish drawn on paper. Its less creative names are Cause-and-Effect Diagram and Ishikawa Diagram. It’s popularly known to help with root cause analysis. But, we can also use it to help with goals and to evaluate a potential solution.

Why is it a Supertool? Just creating its headings helps us to better define our question. Writing it out as a graphical organizer helps organize jumbled thoughts. And, when paired with a 5W2H approach and the 5-whys, it can help us dig to the root causes.

I’ve included some abbreviated examples of fishbone diagrams; click the thumbnail for a larger version (notice that my root causes follow the 5-whys). And, listen to the podcast (or read the transcript) to learn more about Fishbones and their construction and uses.

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 017 What is ‘Production Equivalent’ and Why Does it Matter?

QDD 017 What is ‘Production Equivalent’ and Why Does it Matter?

What is ‘Production Equivalent’ and Why Does it Matter?

We’re in the middle of our design process and we’re getting some of the first parts in hand, from prototyping or benchtops or our manufacturing cell. Let’s test them and finish our verification testing! Maybe we shouldn’t.

We talk about the concept of production equivalent: what it means and when it’s important to consider.

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Filed Under: Quality during Design, The Reliability FM network

by Dianna Deeney Leave a Comment

QDD 016 About Visual Quality Standards

QDD 016 About Visual Quality Standards

About Visual Quality Standards

“A picture is worth a thousand words” is an old saying, and it holds true! Visual standards, visual aids, and quality standards are a great tool, especially in design when communicating the limits of acceptability. This episode explores areas to capture this type of information and how it can be used not just for Quality Assurance and Production, but also for design verification protocols, FMEA, root cause analysis, and future field defect investigations (to name a few).

[Read more…]

Filed Under: Quality during Design, The Reliability FM network

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Quality during Design podcast logo

Tips for using quality tools and methods to help you design products others love, for less.


by Dianna Deeney
Quality during Design,
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Recent Episodes

QDD 165: Redux: 5 Aspects of Good Reliability Goals and Requirements

QDD 164: Supplier Agreements: The Good, The Bad, and The Quality

QDD 163: Practice Makes Improvement in Subjective Probability Estimations

QDD 162: Redux – Quality Tools are Legos of Development (and Their 7 Uses)

QDD 161 Cultivating a Culture of Craftsmanship within Quality Systems

QDD 160 The Mighty Power of Mini Reports

QDD 159 Celebrating a Year of Insights

QDD 158 Social Dynamics with Yakira Mirabito (A Chat with Cross-Functional Experts)

QDD 157 How Engineers Changed Thanksgiving

QDD 156 Predictive Analytics, Machine Learning, AI, and VR in Design Engineering

QDD 155 Improving Communication and the Workplace with Meagan Pollock (A Chat with Cross-Functional Experts)

QDD 154 Myths of Product Development – Part 2

QDD 153 Myths of Product Development – Part 1

QDD 152 Engineering Careers: A Panel Discussion with ‘Brilliant!’ and ‘How to Win Friends and Influence People’’

QDD 151 Revolutionize Your Technical Presentations: Mastering the Assertion Evidence Model and the Six P’s Framework

QDD 150 Prioritizing Customer Satisfaction in Product Design (the Kano Model)

QDD 149 Maximizing Meeting Value and Participation

QDD 148 Data Visualization Tips to Improve Analysis Skills

QDD 147 Effective Team Meetings: From Chaos to Cohesion

QDD 146 Unraveling QA, QC, Quality Assistance, and Quality 4.0

QDD 145 Simplifying Probabilities for Better Decision Making

QDD 144 From Solo to Collaboration: Lessons from Nobel Laureate Shuji Nakamura and Dale Carnegie

QDD 143 Bridging Triumph and Trial: A Panel Discussion about Engineering with ‘To Engineer is Human’ and ‘The Wright Brothers’

QDD 142 What is DFSS and How does Quality during Design Relate?

QDD 141 Exposing The Hidden Flaws of FMEA and Risk Matrices: Advancing Your Risk Assessment

QDD 140 Getting Information for Product Design with Fred Schenkelberg (A Chat with Cross-Functional Experts) – Part 2

QDD 139 Getting Information for Product Design with Fred Schenkelberg (A Chat with Cross-Functional Experts) – Part 1

QDD 138 Harnessing Team Insights for Risk Analysis using Probabilities

QDD 137 From “Fall-Through” to “Follow-Through”: A Proactive Strategy for Design

QDD 136 Welcome Back! New, Upcoming Opportunities with FMEA and Quality during Design

QDD 135 Taking a Brief Pause: Reflecting on Quality During Design’s Journey and Preparing for What’s Next

QDD 134 Timing Reliability in Product Design, with Jeffrey Lewis (A Chat with Cross-Functional Experts)

QDD 133 Driving Effective Conversations-Prioritizing and Decision Making at Concept Development and Beyond

QDD 132 Driving Effective Conversations-Three Major Aspects to Consider for DfX

QDD 131 Driving Effective Conversations-Taking the Lead in Working Meetings

QDD 130 Supply Chain Management during Design, with Kevin Bailey (A Chat with Cross-Functional Experts)

QDD 129 The Strategic Gamechanger: Quality during (Product) Design

QDD 128 Leveraging Proven Frameworks for Concept Development

QDD 127 Understanding Cross-Functional Collaboration

QDD 126 Exploring the Problem Space: A Key Principle for Robust Product Design and Project Success

QDD 125 Exploring Product Development and AI Through Literature

QDD 124 Design for User Tasks using an Urgent/Important Matrix

QDD 123 Information Development in Design, with Scott Abel – Part 2 (A Chat with Cross-Functional Experts)

QDD 122 Information Development in Design, with Scott Abel – Part 1 (A Chat with Cross-Functional Experts)

QDD 121 Crafting Effective Technical Documents for the Engineering Field

QDD 120 How to use FMEA for Complaint Investigation

QDD 119 Results-Driven Decisions, Faster: Accelerated Stress Testing as a Reliability Life Test

QDD 118 Journey from Production to Consumption: Enhancing Product Reliability

QDD 117 QDD Redux: Choose Reliability Goals for Modules

QDD 116 Reliability Engineering during Design, with Adam Bahret (A Chat with Cross-Functional Experts)

QDD 115 QDD Redux: 5 Options to Manage Risks during Product Engineering

QDD 114 The Instant Glory of Projects

QDD 113 What to do about Virtual Meetings

QDD 112 QDD Redux: How to self-advocate for more customer face time (and why it’s important)

QDD 111 Engineering with Receptivity, with Sol Rosenbaum (A Chat with Cross-Functional Experts)

QDD 110 Don’t Wish for Cross-Functional Buy-in on Product Designs – Plan to Get It!

QDD 109 Before You Start Engineering Solutions, Do This

QDD 108 QDD Redux Ep. 4: Statistical vs. Practical Significance

QDD 107 QDD Redux Ep. 3: When it’s Not Normal: How to Choose from a Library of Distributions

QDD 106 QDD Redux Ep. 2: How to Handle Competing Failure Modes

QDD 105 QDD Redux Ep. 1: How Many Do We Need to Test?

QDD 104 The Fundamental Thing to Know from Statistics for Design Engineering

QDD 103 What to do for Effective and Efficient Working Meetings

QDD 102 Get Design Inputs with Flowcharts

QDD 101 Quality Tools are Legos of Development (and Their 7 Uses)

QDD 100 Lessons Learned from Coffee Pod Stories

QDD 099 Crucial Conversations in Engineering, with Shere Tuckey (A Chat with Cross-Functional Experts)

QDD 098 Challenges Getting Team Input in Concept Development

QDD 097 Brainstorming within Design Sprints

QDD 096 After the ‘Storm: Compare and Prioritize Ideas

QDD 095 After the ‘Storm: Pareto Voting and Screening Methods

QDD 094 After the ‘Storm: Group and Explore Ideas

QDD 093 Product Design with Brainstorming, with Emily Haidemenos (A Chat with Cross Functional Experts)

QDD 092 Ways to Gather Ideas with a Team

QDD 091 The Spirits of Technical Writing Past, Present, and Future

QDD 090 The Gifts Others Bring

QDD 089 Next Steps after Surprising Test Results

QDD 088 Choose Reliability Goals for Modules

QDD 087 Start a System Architecture Diagram Early

QDD 086 Why Yield Quality in the Front-End of Product Development

QDD 085 Book Cast

QDD 084 Engineering in the Color Economy

QDD 083 Getting to Great Designs

QDD 082 Get Clarity on Goals with a Continuum

QDD 081 Variable Relationships: Correlation and Causation

QDD 080 Use Meetings to Add Productivity

QDD 079 Ways to Partner with Test Engineers

QDD 078 What do We do with FMEA Early in Design Concept?

QDD 077 A Severity Scale based on Quality Dimensions

QDD 076 Use Force Field Analysis to Understand Nuances

QDD 075 Getting Use Information without a Prototype

QDD 074 Finite Element Analysis (FEA) Supplements Test

QDD 073 2 Lessons about Remote Work for Design Engineers

QDD 072 Always Plot the Data

QDD 071 Supplier Control Plans and Design Specs

QDD 070 Use FMEA to Design for In-Process Testing

QDD 069 Use FMEA to Choose Critical Design Features

QDD 068 Get Unstuck: Expand and Contract Our Problem

QDD 067 Get Unstuck: Reframe our Problem

QDD 066 5 Options to Manage Risks during Product Engineering

QDD 065 Prioritizing Technical Requirements with a House of Quality

QDD 064 Gemba for Product Design Engineering

QDD 063 Product Design from a Data Professional Viewpoint, with Gabor Szabo (A Chat with Cross Functional Experts)

QDD 062 How Does Reliability Engineering Affect (Not Just Assess) Design?

QDD 061 How to use FMEA for Complaint Investigation

QDD 060 3 Tips for Planning Design Reviews

QDD 059 Product Design from a Marketing Viewpoint, with Laura Krick (A Chat with Cross Functional Experts)

QDD 058 UFMEA vs. DFMEA

QDD 057 Design Input & Specs vs. Test & Measure Capability

QDD 056 ALT vs. HALT

QDD 055 Quality as a Strategic Asset vs. Quality as a Control

QDD 054 Design Specs vs. Process Control, Capability, and SPC

QDD 053 Internal Customers vs. External Customers

QDD 052 Discrete Data vs. Continuous Data

QDD 051 Prevention Controls vs. Detection Controls

QDD 050 Try this Method to Help with Complex Decisions (DMRCS)

QDD 049 Overlapping Ideas: Quality, Reliability, and Safety

QDD 048 Using SIPOC to Get Started

QDD 047 Risk Barriers as Swiss Cheese?

QDD 046 Environmental Stress Testing for Robust Designs

QDD 045 Choosing a Confidence Level for Test using FMEA

QDD 044 Getting Started with FMEA – It All Begins with a Plan

QDD 043 How can 8D help Solve my Recurring Problem?

QDD 042 Mistake-Proofing – The Poka-Yoke of Usability

QDD 041 Getting Comfortable with using Reliability Results

QDD 040 How to Self-Advocate for More Customer Face Time (and why it’s important)

QDD 039 Choosing Quality Tools (Mind Map vs. Flowchart vs. Spaghetti Diagram)

QDD 038 The DFE Part of DFX (Design For Environment and eXcellence)

QDD 037 Results-Driven Decisions, Faster: Accelerated Stress Testing as a Reliability Life Test

QDD 036 When to use DOE (Design of Experiments)?

QDD 035 Design for User Tasks using an Urgent/Important Matrix

QDD 034 Statistical vs. Practical Significance

QDD 033 How Many Do We Need To Test?

QDD 032 Life Cycle Costing for Product Design Choices

QDD 031 5 Aspects of Good Reliability Goals and Requirements

QDD 030 Using Failure Rate Functions to Drive Early Design Decisions

QDD 029 Types of Design Analyses possible with User Process Flowcharts

QDD 028 Design Tolerances Based on Economics (Using the Taguchi Loss Function)

QDD 027 How Many Controls do we Need to Reduce Risk?

QDD 026 Solving Symptoms Instead of Causes?

QDD 025 Do you have SMART ACORN objectives?

QDD 024 Why Look to Standards

QDD 023 Getting the Voice of the Customer

QDD 022 The Way We Test Matters

QDD 021 Designing Specs for QA

QDD 020 Every Failure is a Gift

QDD 019 Understanding the Purposes behind Kaizen

QDD 018 Fishbone Diagram: A Supertool to Understand Problems, Potential Solutions, and Goals

QDD 017 What is ‘Production Equivalent’ and Why Does it Matter?

QDD 016 About Visual Quality Standards

QDD 015 Using the Pareto Principle and Avoiding Common Pitfalls

QDD 014 The Who’s Who of your Quality Team

QDD 013 When it’s Not Normal: How to Choose from a Library of Distributions

QDD 012 What are TQM, QFD, Six Sigma, and Lean?

QDD 011 The Designer’s Important Influence on Monitoring After Launch

QDD 010 How to Handle Competing Failure Modes

QDD 009 About Using Slide Decks for Technical Design Reviews

QDD 008 Remaking Risk-Based Decisions: Allowing Ourselves to Change our Minds.

QDD 007 Need to innovate? Stop brainstorming and try a systematic approach.

QDD 006 HALT! Watch out for that weakest link

QDD 005 The Designer’s Risk Analysis affects Business, Projects, and Suppliers

QDD 004 A big failure and too many causes? Try this analysis.

QDD 003 Why Your Design Inputs Need to Include Quality & Reliability

QDD 002 My product works. Why don’t they want it?

QDD 001 How to Choose the Right Improvement Model

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