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Team Lead: Howard Cooper, DFSS-BB, DfR Chuck Roe, DFSS-MBB, DfM April 4, 2013

Applying Structured Innovation “TRIZ” to Manufacturing Challenges. Team Lead: Howard Cooper, DFSS-BB, DfR Chuck Roe, DFSS-MBB, DfM April 4, 2013. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013.

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Team Lead: Howard Cooper, DFSS-BB, DfR Chuck Roe, DFSS-MBB, DfM April 4, 2013

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  1. Applying Structured Innovation “TRIZ” to Manufacturing Challenges Team Lead: Howard Cooper, DFSS-BB, DfR Chuck Roe, DFSS-MBB, DfM April 4, 2013 Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  2. Introduction to Rapid Structured Innovation Introduction to the GDLS Mfg Innovation Tool Application of Tool to “Working Knowledge” level. Example: GDLS DFM Mfg problem Case Study Summary (Benefits in Time & Manufacturability) Questions & Answers Overview – Applying Innovation Tool for DfM and Manufacturing Problems Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  3. What is “TRIZ” ? • A Russian acronym: TheoriaResheneyvaIsobretatelskehuhZadach (Theory of Solving Inventive Problems) Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  4. Where Theory of Solving Inventive Problems (TRIZ) can be applied • Many industries and discipline, some include but are not limited to the following: • Manufacturing • Sales • Marketing • Engineering • Process Design & Control • Software Design • Healthcare • Design for Manufacturing (DfM) Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  5. TRIZ, Structured Innovation, Combined with • TRIZ Tools can bring great leverage to, reduce time for and amplify the effect of other tools, including but not limited to the following: • Brainstorming • Six Hats • QFD • Six Sigma • Lean Mfg • SS DMAIC • DFSS Tools • Problem Solving in General Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  6. Creativity - Innovation - Rapid Structured Innovation Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  7. 4 Steps to Innovative Problem Solving Innovative Structured Thinking Solution Path Brainstorming Experimenting Waiting for the big ahah! Define Specific Problem General Contradiction General Solution Principle Specific Solution Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  8. TRIZ = 3 Key Tools, the Process & Language TRIZ Matrix Solving System Conflicts Applying Resources Solving Physical Conflicts Patterns of Evolution Predicting Next Innovation Mfg-TRIZ Tool ARIZ-85c Process for TRIZ Su Field 76 Patterns Language of TRIZ Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  9. Adding the 33 Innovation DFR Principles • GenrichAltshuller (1926 – 1999) the Father of TRIZ analyzed over 200,000 Patents and discovered that they all solved conflict between two or more of only 39 design parameters or characteristics. • Manufacturability is one of these 39 parameters • On all 200,000+ patents, these Conflicts were corrected or solved using just one or two of only 40 design principles. • Of these 40, 34 principles solve Manufacturability and DfM problems • What should we do with these 34? Introduction Mfg-TRIZ Tool, for Rapid Structured Innovative Solutions Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  10. Introducing the Mfg-TRIZ Tool Which of the 39 Parameters (left column) is negatively affecting Manufacturability? Right-hand ‘blue’ numbers show which DfM Approach to use, from the following slides. (Mfg-TRIZ Reference) Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  11. A longstanding reoccurring mission critical failure, caused by a manufacturing quality issue, was solved in less than 35 minutes. Recent DFM Mfg-TRIZ Tool Application (Example – Case Study) Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  12. Problem: 1 of 8 “catch & drag” Stops on parallel telescoping rails, occasional failure 7 of 8 Stops with no Problem Reoccurring Problem Since 2003 Adding Epoxy to hold the screwed on Stop did not solve the problem. Frequently Seen Failure Mode: Rail catch & drag “stop“ in 7th position is forced or sheered off the rail. No failures on opposite stop nor any other stops. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  13. Asking Wrong Question Yields Wrong Solutions • How can we keep the Stop from sheering off the rail? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  14. Ask the right question – TRIZ yields the right solutions • How can we keep the Stop from sheering off the rail? • What is the design parameter conflict? • What approach could remove the conflict? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  15. TRIZ Tool Focused on Both Force & Pressure; 10 & 11 Six Design Principles to help solve the Problem: 3, 35, 13, 21, 10, 19 Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  16. 4 Steps to Solving Problems with TRIZ Stops sheering off the rails Reliability vs. Force / Pressure Define Problem The Problem’s Parameter Contradiction 39 Parameters 40 Principles 3, 35, 13, 21, 10, 19 Specific Solution Generic Solution(s) 1 or 2 Best Principles Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  17. Brainstorming TRIZ Principle: 3, 35, 13, 21, 10, 19 • Principle #3 Local Quality • A. Transition from homogeneous to heterogeneous structure of an object or outside environment (action). (Stop, screw or epoxy?) • Different parts of an object should carry out different functions (Already Doing) Maybe tougher or more flexible screw or epoxy? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  18. Brainstorming TRIZ Principals 3, 35, 13, 21, 10, 19 • Principle #35 Transformation of Properties: • A. Change the physical state of the system. • B. Change the concentration or density. • C. Change the degree of flexibility. • D. Change the temperature or volume. Maybe tougher or more flexible screw or epoxy? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  19. Brainstorming TRIZ Principals 3, 35, 13, 21, 10, 19 • Principle #13 Do It In Reverse • A. Instead of the direct action dictated by a problem, implement an opposite action (i.e., cooling instead of heating). • B. Make the movable part of an object, or outside environment, stationary - and stationary part of movable. • C. Turn an object upside-down This is what the sliding rails already do Hmmm. . . This may suggest Trimming? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  20. Brainstorming TRIZ Principals 3, 35, 13, 21, 10, 19 • Principle #21 Rushing Through • A. Perform harmful and hazardous operations at a very high speed. Forget that Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  21. Brainstorming TRIZ Principals 3, 35, 13, 21, 10, 19 • Principle #10 Prior Action • A. Perform required changes to an object completely or partially in advance. • B. Place objects in advance so that they can go into action immediately from the most convenient location. 2. Use Bolt not Screw (larger diameter) 3. Add a hardened pin 4.Seat Stop deeper into rail 1. Replace Stops before every mission? X Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  22. Brainstorming TRIZ Principals 3, 35, 13, 21, 10, 19 • Principle #19 Periodic Action • A. Replace a continuous action with a periodic action (impulse). No. I don’t think so. . . Not practical Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  23. Combine TRIZ Principals 3, 10 & 35 #13 later #13 Do It In Reverse, upside-down, or inside-out. Hmmm . . . #10 1. Use Bolt not Screw 2. Add a pin 3.Seat Stop deeper into rail #3, #35 Maybe tougher or more flexible screw or epoxy? Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  24. Compare Concepts to Ideality Contradictions Known? Perform Function Modeling Decompose Function Model Identify Contradictions Define Ideal Solution No Define Problem Yes Brainstorm Using Priority & Mode of Principles Identify TRIZ Principles for Contradiction Resolution Affinitize Ideas/ Develop into Concepts Recommend Solution Concepts Comparable to Ideality ? Brainstorm Base on SME Yes No Compare Concept to Ideality Ideality: Perform “catch & drag” function without the Stops Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  25. Ideality & Principle #13 Suggest • Simplify design by transferring function of “catch & drag” from the “Stops” to the Rails • Principle #13 Do It In Reverse • C. Turn an object upside-down • New Concept: Machine or mold the Stops into the Rails • One piece construction • No assembly labor for Stops • Rails can handle and disperse the instantaneous engagement shock Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  26. Now That’s an Idea! And its “Lean” Transfer “catch & drag” function of Stops to the rail. #13 Do It In Reverse, upside-down, or inside-out. Ideality: Do Catch & Drag Function without add-on “stops.” Manufacturability – no assembly time Ideal Reliability Slide stops machined as part of the slide rails. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  27. No “Stops” added to Rails Ball bearings & holder glide between rails. Ideality: Do Catch & Drag Function without add-on “stops.” Bearing ‘ways’ are machined into the rails. No add-on bearing ways. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  28. Ball bearing holder glides between rails. Bearing ‘ways’ are machined into the rails. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  29. Charateristics: Bearing ways, part of rail. Only 4 Rail Components. “Stops” part of rails Benefits: Very little assembly Fewer Parts More Reliable Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  30. DfM Innovation Tool Advantages Original Concept-1 Concept-2 Total Structured Innovation Tool usage time to generate 2 solution concepts: 35 minutes Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  31. Case Study Summary – DFM by Innovation A 35 minute structured innovation session using this innovation tool provided a new design with: • Bearing ways machined into each rail section • Design cheaper to manufacture • Cheaper to assemble • 4 to 1 part count reduction • More effective in function • Improved reliability Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  32. ROI Results • Reduced failure rate of the rails, along with reduced manufacturing and assembly cost resulted in a total lifecycle cost reduction of $658,012: Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  33. Audience Takeaways • Understanding of how you can construct your own rapid structured innovation Tool for more efficiently deriving effective solutions to Lean manufacturability problems. • Working knowledge on how TRIZ rapidly links you to the best principles and approaches from over 200,000 patents to solve current Lean manufacturability or productivity problem. • Access to resources for developing and integrating rapid structured innovation into your ISO-9001 or GD IPS Process, to prompt use at key points in the manufacturing process. Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

  34. Apply Rapid Structured Innovation Tools to Mfg Challenges Team: Howard C Cooper, DFSS-BB, DFR cooperh@gdls.com 586-825-4977 Chuck Roe, DFSS-MBB, DfM roec@gdls.com 734-895-5464 Approved for Public Release, Distribution Unlimited, GDLS approved, Log No. 2013-18, dated 2-27-2013

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