Design for DFX April 15, 2015 Mark Rockwell Geno Scalcucci John Murphy Drew Kamerzell

1. Design for DFX April 15, 2015 Mark Rockwell Geno Scalcucci John Murphy Drew Kamerzell A guide to creating effective documentation for all DFX’s

2. How this lesson works Scope Ingredients Case Study Explanation of purpose and goals of the ingredient Description of how a DFX case study should look The Problem Good/poor examples pulled from existing DFX lessons Lesson Goals DF Poka Yoke reimagined per suggested DF DFX structure Demonstration of ingredient for explaining DF DFX Reflection on the process

3. DF DFX Goals • Create a structured guideline that can be applicable to all DFX’s with allowance for easier use, understanding, and comprehension by future readers. • Streamline the DFX lesson format to encourage better edification and course experience in future classes. • Encapsulate and discuss the entire development process as it applies to DFX, involving as many departments within an organization as needed. • This DF”X” presentation will be used as a guideline for future users creating coursework for DFX.

4. Current DFX Problem • Existing DFX presentations were created by many different people with different creative direction and therefore very different styles. • This forces users to recalibrate their thought processes as they traverse between DFX subjects and impedes the ability of the reader to absorb the content. • Different formats and presentation structure leaves holes in the subject matter and inconsistency in the way the subject matter is presented.

5. Proposed Solution • Standardization makes the presentations more readable for users, maintains a consistent arrangement of core information, and facilitates absorption of information when reading/reviewing multiple DFX’s. • The key ingredients every DFX will need to effectively reach the target users are: • How the specified DFX is used • How to apply the DFX lesson in practice

6. DF DFX Assumptions • 85% of the reading audience are graduate students with little or no experience with defined “X”’s. • DFX should read like a book presented in Google Sheets. • These documents are not an aid to a presentation but a means to educate • They are standalone documents with linked references • NO PROPRIETARY INFORMATION!

7. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • What are the measures of failure and success • Highlight simple real world examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Study(s)

8. Define the X: Slide Goals • Summarize what is the X to be outlined • High-level definitions of the X • Cite from industry/sources other definitions for the X for different perspectives on the X

9. Define the X: Examples • Good Examples • DF Serviceability: the ability of a technician to service a particular component of a system (IE, an automobile transmission or computer hard drive). • Bad Examples • No definition given • DF Poka-yoke: “is Japanese for mistake proofing” • How does this help the reader? • Not cited.

10. DEFINE DFX • “Under the label Design for X, a wide collection of specific design guidelines are summarized. Each design guideline addresses a particular issue that is caused by, or affects the characteristics of a product. The design guidelines themselves usually propose an approach and corresponding methods that may help to generate and apply technical knowledge in order to control, improve, or even to invent particular characteristics of a product”1

11. DEFINE DFX • DFX is a guideline that allows the user to design for the X. • DFX is designing to prevent a failure or an undesirable condition of the particular “X”. • DFX is making sure that the design functions as intended in all circumstances

12. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

13. Define “Design for X”: Slide Goals • Outline what it means to design for the chosen X • It is important to capture not only what the X is but what Designing for X entails • Why is important to design for this X - what needs to accomplished or what error state needs to be avoided • It is important to give a good definition that not only defines the “design for X” but delineates between the definition of the X and the design for X

14. Define “Design for X”: Examples • Good Example: • DF Environment: A systematic consideration of design performance with respect to environmental, health, and safety objectives, over the full product and process life cycle • Bad Example • Many DFX’s gloss over this part of the lesson assuming defining the X is good enough. However, just because someone knows what the testability is doesn't mean they are able to design for testability.

15. What is Design for Design for X • The organization of information • Create a DFX that formalizes how to create or reformat a DFX presentation. • The “X’ in DF X suggests that the X is a variable term that can be substituted with any number of “functions”: Assembly, Cost, Fabrication, Manufacturing, Reliability, Serviceability Etc.

16. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

17. How to Design for X • This slide should describe to the reader how to design for the X. It is a high level summary of the process. The detailed step by step process will be described in the How to Apply DFX section. You as the expert should take into account all appropriate steps needed to design the X properly and describe in detail with guidelines for the reader to follow. All tools and techniques needed to DFX are described. Any additional DFX’s that should be worked in parallel are also noted.

18. How to Design for X • GOOD • The reader can clearly understand the DFX process. They can follow the DFX process after reading the case study. The reader should be able to describe and explain the process after reading the DFX. • POOR • The DFX contains no description of how to design for X. • The reader gained no knowledge or ability to explain the X.

19. How to Design for X: DFX These guidelines should be used when designing for DFX • The DFX should define the X • The DFX should define the design for X • The DFX should give examples of failure and success • The DFX should provide real world examples of the X • The DFX should provide reasons for why you care about the design for X • The DFX should provide detailed process of how to apply the DFX • The DFX should provide key considerations • The DFX should include case study examples

20. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why You Care • How to Apply DFX • Key DFX Considerations • Case Studies

21. Measuring failure and success: Slide Goals • It is important to indicate what determines good or poor DFX. These measures supply a metric for a user to objectively indicate their strength or weakness in the implementation of a particular DFX. • Measures of success and failure vary greatly between different DFX’s, take into considerations the different stakeholders involved with your particular DFX and ask questions like these: • How is a stakeholder’s interaction with a design changed based on the selected “X”? • Is there a tangible difference versus designs in existence? Why? • The answer to why will lead to measurable levels of success that can be used to indicate success/failure. • Degrees of success/failure should be objectively measurable • In addition, when all DFX’s have objective metrics a user will be able to access their design and progress at different points in their process and determine where the product/concept is strong/weak and what elements have opportunity for improvement.

22. Measuring failure and success: Examples • Good • DF Ergonomics: Discussion of objective measurements needed for Anthropometrics (slide 24). Discussion on objective measures that have been developed over time to determine if a concept has good design for ergonomics elements • Poor • Objective measures not given • Subjective or muscle memory examples provided. • Missing examples of how someone with little experience could review a concept and determine how well/poor a particular DFX is implemented

23. Measuring failure and success: DF DFX • Provide methods of how to measure the quality of implementation for chosen DFX • Create a simple questionnaire about chosen DFX • Survey people w/ and w/o DFX lesson support • Compare and use results to indicate where your lesson is strong and weak • Using this presentation as a template ensure your DFX contains all ingredients necessary to create a well-rounded lesson

24. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

25. Real World Examples: Slide Goals • These are short examples that can give the user a quick example of how a particular DFX is used in daily life. • Very high level and simple. • Cite sources and link references where possible. • Goal is to to ground the audience with examples that capture the DFX based on the discussion in the lesson to this point.

26. Real World Examples: Examples • GOOD • DF Customization: “vintage PC’s required the user to manually install software drivers and alter BIOS settings when installing different hard drives, video cards, etc.”

27. Real World Examples: Examples • POOR Example Suppose a worker must assemble a device that has two push-buttons and a spring under each button. Sometimes a worker will forget a spring. A simple poka-yoke device was developed to eliminate this problem: • The worker counts out two springs from a bin and places them in a small dish • After assembly is complete, if a spring remains in the dish, the operator knows an error has occurred HOWEVER: The operator has no way of knowing if one of the springs fell out of the dish, if both springs were put into the same button, the springs were put into the buttons correctly and then one of them fell out en route to being installed. The best way to poke yoke this would be to have the push-button molded around the spring to ensure presence at all times (this process is also easily poka yoke’d)

28. DF DFX Example Taxonomy of DFX template 4

29. DF DFX Example Source: Guide to Course Design INITIAL DESIGN PHASE: Build Strong Primary Components Step 1. Identify important situational factors Step 2. Identify important learning goals Step 3. Formulate appropriate feedback and assessment procedures Step 4. Select effective teaching/learning activities Step 5. Make sure the primary components are integrated INTERMEDIATE DESIGN PHASE: Assemble the Components into a Coherent Whole Step 6. Create a thematic structure for the course Step 7. Select or create an instructional strategy Step 8. Integrate the course structure and the instructional strategy to create an overall scheme of learning activities FINAL DESIGN PHASE: Finish Important Remaining Tasks Step 9. Develop the grading system Step 10. De-Bug possible problems Step 11. Write the course syllabus Step 12. Plan an evaluation of the course and of your teaching3

30. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

31. Why You Care: Slide Goals • Why do you need this part of the presentation? • To ensure the information being presented reaches out to the target audience. • What value does it add? • To have the target audience walk away with the gained knowledge and be able to apply principles from the DFX reviewed obtain additional reference material. • What should it accomplish in driving home the lesson of your chosen DF DFX? • The knowledge and skill sets presented are gained and can be applied.

32. Why You Care: Examples • Good • Why does it matter to you? • All the work placed in creating the DFX should not be wasted. Knowledge placed in presentation should be shared, learned, and expanded upon. • Poor • Why does it matter to you? • The presentation material doesn’t mesh well and target audience doesn’t gain the knowledge potential from the material.

33. Why Your Customers Care about DF DFX? • Why does it matter to your customer? • When using the DFX your customer may notice part variation, a squeak or rattle, a water or wind leak, a major component failure. These are some of the issues you must address when designing for the X. • When using DFX the assembly plant will also be affected. If a part is designed in a way in which it could be incorrectly built or very difficult to build.

34. Why Your Stakeholders Care about DF DFX? • Why does it matter to other stakeholders? • The stakeholders must be addressed in the DFX. There are many stakeholders in that are affected by the design. Suppliers, service, endcustomer, management, testing etc. • Keep the stakeholders in mind to manage their influence in relation to the requirements to ensure a successful project.

35. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

36. How to apply DFX: Slide Goals • The reader should now have all the necessary background for how to apply the X. To further explain how to design for the X, you should detail the step by step process of how you, the expert, designs for the X.

37. How to apply DFX: Examples • GOOD • Each step of the DFX process is defined in understandable terms. • The reader can easily follow the process. • The process is not missing any steps. • The process is in a logical order. • POOR • The DFX contains no process of how to design for the X. • After reading the process the reader can not properly complete a design using the DFX process.

38. How to apply DF DFX • The DFX should-guidelines should be flexible and be adaptable to changing situations • DFX - guidelines should be aware of the dependencies between contradicting DFXs • DFX - guidelines should support the early and all of the development phases • DFX - guidelines should include steps to review all related DFX and if possible work together in parallel • DFX - guidelines should include any definitions that the average student would not know • DFX - guidelines should look at impacts to stakeholders • DFX process should be well defined, complete and not missing steps • After reading this DFX the reader should be able to follow the guidelines to create a DFX of their own

39. How to apply DF DFX Where possible, the DFX should follow a consistent general outline for better reading consumption by the end users reading multiple DFX’s. Here’s a recommended outline: • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

40. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

41. Key Considerations: Slide Goals • The key considerations element of your DFX lesson is an opportunity to recapture highlights of the entire lesson. Highlighting pieces of information you want everyone to walk away with after reading your lecture. • Focus on simple and easy examples that any user can implement nearly immediately in the real world with your DFX in mind. • Link to other DFX’s that are relevant to your chosen DFX. Most of the DFX’s relate to each other in some aspect or another. It is important to highlight this DFX to other DFX’s and discuss how they work together. • Reiterate the importance of stakeholders relationship with the DFX. Arguably one of the most important considerations with all DFX’s is how they relate to all of the relevant stakeholders.

42. Key Considerations: Examples • Good • DF HV Battery Sizing: Recap key points for DF HV Battery for temperature control as it relates to other DFX’s • Poor • Recap not present • Considerations don’t refer back to previously mentioned material (first time information is mentioned) • No discussion of how different stakeholders are affected

43. Key DF DFX Considerations • Consider the applicability of other DFX subject matter to your topic. With this you take advantage of other existing resources to help educate your audience on your topic. • The ability of the audience to understand the content is the prime consideration. If the intent of the lesson is unclear to them, then the content needs to be revised. • NO PROPRIETARY INFORMATION

44. DF DFX Relation to other DFX’s • DF Cohorts: DFX is an elective in the MPD program understanding how designing for DFX should fall within the scope of what makes good DF Cohorts. • DF Product Evolution: Design the DFX lesson with the understanding that future classes will review, learn, update, and expand • DF Testability: Good DF DFX is measurable and has the ability to self check itself to ensure the user is digesting the material

45. DF DFX Course Outline • Define The X • Define the Design for X • Define how you Design for X • Measuring DFX Failure and Success • Simple Real World Examples • Why you Care • How to Apply DFX • Key DFX Considerations • Case Studies

46. Case Study: Slide Goals • Case studies are in depth examples of the application of particular DFX in practice • The goal is to deep dive and explain in detail how a DFX was taken into consideration when generating a concept or design • Case studies will pull together the ingredients demonstrated through the first part of the lesson and mix them together into a complete meal for the reader to consume • Case studies can be actual examples from industry, projects conducted in other coursework, or exposes on what should have been done

47. Case Study: General Outline • Case Background and History • Summary and scope of what the case study is and necessary context to demonstrate DFX to given example • What is the problem? • Highlight the primary issue in the case and how DFX could be applied to rectify the situation or improve the product • Strength/Weakness of Case • What are the pros/cons of the given system

48. Case Study: General Outline • Key DFX Considerations and attributes • Prior to application of DFX highlight needs and features that are in need of DFX. What are signs that DFX is needed to improve • How your DFX was implemented • Using pieces from the original explanation and breakdown of DFX walk through examples and steps of how the DFX was implemented to improve the process • Key take aways for your DFX • What have you learned and what can the user take away from this study to help apply the given DFX in their lives

49. DF DFX Case Study: DFA5-Poka Yoke Background and History • Design for Assembly (Part 5); DFA5: Poka Yoke is being chosen for our case because it stood out as one that could be shown to benefit from following DF DFX guidelines. • Link to original DFX Lesson

50. DF DFX Case Study: DFA5-Poka Yoke Problem Statement • The Design for Assembly Part 5 (DFA5); Poka Yoke didn’t follow the original outline in slide #2. Also, when this file is read as a stand alone file (apart from the other DFA’s) it felt disconnected. • The original slide #3 defines the term as Poka-Yoke, and majority of the slides refer to it as “Poke Yoke”. Consistency is important. • A simpler DFX that shows the benefits of DF DFX.