Q UALITY THROUGH INNOVATION: Theory of Inventive Problem Solving

1. QUALITY THROUGH INNOVATION:Theory of Inventive Problem Solving Gülser Köksal Industrial Engineering Department Middle East Technical University 2008

2. FAILURE OF NEW PRODUCTS • 70-80% of new products do not survive • Top companies get 39-50% of revenues from new products, while less successful companies get only 23% • Leading cause of failure : Copying competitors’ new products

3. THEORY OF INVENTIVE PROBLEM SOLVING (TRIZ) • G. Altshuller studied more than 1,500,000 world-wide patents. • He extracted from these 39 engineering parameters that cause conflict. • Her also extracted from these 40 inventive principles. • He showed that over 90% of the problems engineers faced had been solved somewhere before.

4. LEVELS OF INVENTIVENESS LevelDeg. of invent. % of Know.Source # of solutions solutions to consider 1 Apparent solution 32% Personal knowledge 10 2 Minor improvement 45% Know. within company 100 3 Major improvement 18% Know. within industry 1000 4 New concept 4% Know. outside industry 100,000 5 Discovery 1% All that is knowable 1,000,000

7. Innovation and TRIZ Could you reverse the fish by relocating four sticks sliding them parallel to their axes? Could you reverse the fish by relocating three sticks sliding them parallel to their axes?

8. 39 System Parameters • Weight of moving object • Weight of nonmoving object • Length of moving object • Length of nonmoving object • Area of moving object • Area of nonmoving object • Volume of moving object • Volume of nonmoving object • Speed • Force • Tension, pressure • Shape • Stability of object • Strength • Durability of moving object • Durability of nonmoving object • Temperature • Brightness • Energy spent by moving object • Energy spent by nonmoving object • Power • Waste of energy • Waste of substance • Loss of information • Waste of time • Amount of substance • Reliability • Accuracy of measurement • Accuracy of manufacturing • Harmful factors acting on object • Harmful side effects • Manufacturability • Convenience of use • Repairability • Adaptability • Complexity of device • Complexity of control • Level of automation • Productivity

9. The Most Frequently Used Ten Inventive Principles 35. Parameter changes(Transport oxygen or nitrogen or petroleum gas as a liquid, instead of a gas, to reduce volume) 10. Preliminary action(Pre-pasted wall paper) 1. Segmentation(Modular furniture) 28. Mechanics substitution(electronic voting) 2.Taking out(Locate a noisy compressor outside the building where compressed air is used 15.Dynamics(Adjustable seat) 19. Periodic action(Replace a continuous siren with a pulsed sound) 18.Mechanical vibration(Destroy gall stones or kidney stones using ultrasonic resonance) 32. Color changes(Colormatic lenses) 13. 'The other way round'(Walking stairs)

10. Contradiction Matrix Solution: Short Car Contradiction: Improving parameter: Length of moving object (3) Worsening parameter: Harmful side effects (31) Inventive principle: Another dimension (17) Solution: Mercedes-Swatch made Smart Car Source: Popular Science, January 1998, p.82.

11. Example: How to redesign a beverage can to reduce the cost? CONFLICT: The can wall must be thinner to reduce cost (eng. parameter #4: length of a stationary object) and thicker to improve load bearing capacity (eng. parameter #11: tension, pressure). Source: Glenn Mazur www.mazur.net/triz

13. Inventive principles #1 segmentation, #14 spheroidality, and #35 change physical or chemical parameters can be applied. SOLUTION: Corrugate the wall (segmentation), add a curve from can wall to top (spheroidality), and use a stronger metal alloy (chemical parameter). Source: Glenn Mazur www.mazur.net/triz

14. Evolution Patterns of Technological Systems Trend 1 - Technology follows a life cycle of birth, growth, maturity, decline(airplanes) Trend 2 - Increasing ideality(evolution of computers) Trend 3 - Uneven development of subsystems resulting in contradictions.(speed of computers vs. modem lines) Trend 4 - Increasing dynamism and controllability(manual gearbox to CVT) Trend 5 - Increasing complexity, followed by simplicity through integration(evolution of stereo music systems) Trend 6 - Matching and mismatching of parts(automatic brake system) Trend 7 - Transition from macrosystems to microsystems using energy fields to achieve better performance or control(cooking systems) Trend 8 - Decreasing human involvement with increasing automation(clotheswashing systems)

15. S Curve Sales (System Characteristics) 1. Manual attempts to fly fail. 2. Wright Brothers fly at 30mph in biplane. 3. Military use in WWI. Financial resources available. Speeds increase to 100mph. 4. Wood and rope frame aerodynamics reach limit. 5. Metal frame monoplane developed. 6. Several new types of airplanes have been developed but limited use of biplanes still exists. Maturity 4 5 Decline Growth 3 6 2 Birth 1 Time

16. An Application of Trend 7 to dishwasher technology evolution Segmentation of substances and objects Using sound waves, microwaves Washing with water Using steam

17. An Application of Trend 7 to dishwasher technology evolution Surface segmentation Using lotus effect surfaces in dishwasher walls and utensils Current surfaces of dishwashers and utensils

18. CONCLUSION • Since TRIZ can help engineers and developers solve technical contradictions and invent new technologies, it's use in New Product Development is very important. • Combined with Quality Function Deployment (QFD), a company should be able to identify important customer requirements and then solve any technical bottlenecks that arise. TRIZ can also help identify new functions and performance levels to achieve truly exciting levels of quality.