Engineering Process Improvement Model

Engineering Model is a collection of process elements and principles that can be used as a pattern for Engineering process development and a criterial against which a process can be defined.

ISO 9001: Requirements

• Quality Management • Project Needs/Conceptual Study• Industrial Standards• Project Management Plan• Design Development• Design Validation• Cost Management

TQM

Engineering Approaches

Engineering Approach is a system of tools that is been used to guide problem solving, management and other engineering procedures.

• Total Quality Management: It is a way of managing people and business processes to ensure customer satisfaction at every stage of the engineering process.

Customerfocus

Planning Process

Project Management

Process Improvement

All Staff parti cipati on

Engineering Approaches

Lean Engineering: A process of eliminating the non-value added waste in the product development process. In the lean engineering, three elements must be integrated to create a valuable product and process development systems - IPPD

Lean Engineering Principle

LEANIPPD

TOOLS ANDTECH

SKILLEDPEOPLE

ENGINEERING PROCESS

Lean Engineering Process

Six Engineering Wastes:

Over- production- Analysis, report, tests not needed.

Inventory- Unfinished analysis, reports, test.

Unnecessary Movement- “Stop and Go” task. Working on too many projects at a time.

Waiting- Waiting for decisions or waiting for input.

Defective Outputs - Rework due to wrong requirements or input.

Unused employee creativity- Not engaging engineers in process improvements for engineering.

Product Development Lead Time

Waiti

ng

Define product

Approva

l

Product

Design

Modifica

tion

Man

ufactu

ring

Design Chan

ges

packa

ging

Delivery

Completion0

2

4

6

8

10

12 TIME vs PROCESS

Non-Value added time(WASTE)

Value added time

Product Development Lead Time

Value added time is a small percentage of the lead time.

Project cost savings focused on only Value Added process.

LEAN focuses on Non-Value Added process

Lean Engineering Tools

Engineers should work together as integrated Product Teams. They are responsible for the development, analysis and decision making in the product design process. Engineers should also be involve in about 80 percent or more in or real value-added work. Integrated digital tools reduce wastes of handoffs and waiting, and increase quality• Mechanical (3-D solids design tools)• Software development environments/Model-Based Engineering

Common parts / specifications / design reuse

Design for manufacturing and assembly (DFMA)

Dimensional/configuration/interface management

Testing (only OEM)

Product Lifecycle Management (PLM)software

Engineering Approaches

Six-Sigma Engineering (DMAIC): This is a process improvement methodology which includes different stages integrated with one another to enhance the engineering design process performance. This process help in eliminating defects in design process.

Define

Measure

AnalyseImprove

Control

Six-Sigma Methodology

The methods used to describe Six-sigma application are divided into 5 phases:

Define Phase: The design phase sometimes called the design phase, is the phase where the goals of the engineering improvement are clearly defined.

Parameters which vastly influence determine the enterprise goals in respect to quality Critical to Quality (CTQ)

• Voice of the Customers (VOC)o Brain Storming

Measurement Phase: This phase involve the past data collected on CTQ. The mean average of all the observations is stored in a date set, and this is useful in the process capability index. Performance parameters.

Analyses Phase: In this phase a critical analyses is carried out to defined performance goals, process baseline and variation identifications. Problem root cause

Six-Sigma Methodology

Improvement Phase: This phase is the step where creative solutions to existing problems can be developed and tested using different techniques. It is about verification and validation of recommendations.

Control Phase: This phase is to ensure a successful implementation of the team recommendations so that long-term success will be achieved. The new and improved process will be represented with a flow chart, and these new standard will become the new standard operation procedures.

Project & Process Management Decision Making Tree

Review the key Metric Control

Chart

Investigate Special cause and Stabilize

Process

Is the process Stable?

Are results Good

Enough?

Monitor Process

Start Process Improvement

Has Six Sigma been assigned?

What DMAIC step

Team Working on

DefineSponsor,

Scope, Process Map,

Stakeholders

Measure

Operation definition, Collect data

AnalyseRoot causes and

Effect

ImproveBrain Storming,

Test results, Process pattern

Control Handoff plan,

Audit plan, Training plan, reaction plan.

No

Yes

No

Yes

Yes

No

Engineering Process Improvement

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