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COURSE DETAILS

Globalization has created a "Highly Competitive, Go Fast World", the 1st rule of business is now: "The competitor who Consistently, Reliably and Profitably provides the greatest value to customers FIRST wins"; and the 2nd rule is: "There are NO OTHER RULES". In this climate, even companies who have adopted the philosophies of Highly Accelerated Testing are finding that much more is needed to remain competitive. Other companies who have tried cost cutting and outsourcing strategies have been burned by program delays, hidden costs and quality or reliability problems.

WHO SHOULD ATTEND

Engineering and management personnel involved in product design, development validation and manufacturing processes.

BENEFITS

This course will review the traditional approach to product development, reliability growth and quality Management and compares them to contemporary techniques for accelerating the entire product development process from product concept inception to production launch. This includes benchmarking features of the Toyota Lean Product Development Process that has been credited with making Toyota's product engineers four times more productive than their competitors. This is a process that when coupled with their famed Lean Production System, has made Toyota the undisputed world leader in accelerated product development and product QRD. A review of leading edge QRD integration techniques and how to incorporate them into accelerated product development processes will then be addressed.

The course provides an overview of Toyota’s culture for: integrating and optimizing; people, processes and tech-nology. This involves developing engineers and management with towering technical competence and a fervent commitment to continuous improvement, process optimiz-ation, and driving out waste. These attributes enable Toyota to design the majority of their products “Right On the First Attempt” which ultimately improves organizational efficiency by a factor of 4. This significantly reduces development time and costs over western product development processes based on the Design-Build-Test-Fix (DBTF) model.

OBJECTIVES

The course also covers the Physics of Failure approach of practical engineering and material fundamentals, tools and techniques for practicing product designers and engineers that enables designing inherent QRD features and characteristics into products and their fabrication processes. Topics covered will include: acquiring and managing the fundamental knowledge needed to truly achieve QRD by Design, virtual validation, identification of Critical To Quality (CTQ) criteria and how they can be controlled by Direct QRD Assessment Technologies. The majority of the course's case studies and examples will focus on electrical/ electronic (E/E) technologies.

COURSE OUTLINE

• Introduction
  • The Need for Accelerated Product Development
  • Faster, More Capable Product
  • Development Processes
    
    
• Overview of QRD Tactics in Traditional Western Product Development Processes
  • D-B-T-F
  • The Limits of Testing
  • The Realty of the Reliability Bath Tub Curve
  • Product’s Life Cycle Reliability Growth
    
    
• The QRD Tactics of the Toyota Product Development System
  • Overview of Toyota
  • Product Development Processes
  • The Role of People and Culture
  • Tools & Technologies
  • Predictive Methods
  • Addition Resources for Toyota Processes Information
    
    Lunch Break
    
    
• Reliability Physics/Physics of Failure
  • Term and Definitions
  • Generic Failure Categories (i.e. Why Thing Break)
  • Errors and Variation
  • Overstress
  • Wear out / Damage Accumulation
    
    
• Design for Reliability Tactics
  • PoF Reliability Assessments
  • Virtual Validation - Computer Aided Durability Modeling
  • Computer Aided Product Development Examples
    
    
• Advance Testing Tactics
  • PoF and Highly Accelerated Testing
    • SAT - Simulation Aided Testing
    • SGT - Simulation Guided Testing
  • Direct QRD Assessment Testing of Critical to Quality Criteria
    
    
• Tactics for Production Processes.
  • The 5 Most Common E/E Device Manufacturing/Assembly QRD Issues
    
    
• Q&A, Conclusions & Class Wrap.