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Functional Analysis, application to new product development

Functional Analysis, application to new product development Hervé SALKIN – September 2005 herve.salkin@isuga.fr. 1- Introduction to Functional Analysis 2- Various analysis methods : “RESEAU”, “SAFE”, “FAST” 3- “FMEA” applications 4- Reliability and safety of systems

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Functional Analysis, application to new product development

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  1. Functional Analysis, application to new product development Hervé SALKIN – September 2005 herve.salkin@isuga.fr

  2. 1- Introduction to Functional Analysis 2- Various analysis methods : “RESEAU”, “SAFE”, “FAST” 3- “FMEA” applications 4- Reliability and safety of systems 5- Value analysis techniques

  3. 1- Introduction to Functional Analysis

  4. NATURE OF PRODUCTS • PRODUCT (object, system, assembly) • PROCESS (manufacturing process) • PROCEDURE (organisation procedure) • SERVICE (combination real & virtual)

  5. SUBJECTIVE Image Fashion Life style Comfort Esthetics Classissism Originality Atmosphere Elegance Luxury OBJECTIVE Service Use Performances Characteristics Ergonomy Safety Reliability Availability Durability Maintenance NEED

  6. NEW PRODUCT Observed need Created need Search for main functions Market survey -qualitative -quantitative Marketing specifications Objectives -quality -cost -delivery time -main options Program sheet Functional analysis Functional specification

  7. MARKETING SPECIFICATION • Market qualitative expectation • Main use functions • Competition survey (price, performance, distribution, after sales, ...) • Market segmentation • Commercial product life • Quantitative market study • Sales price • Agent commissions, other costs • Distribution network • Export possibilities

  8. PROGRAM SHEET • INTRODUCTION • Generalities, project presentation • OBJECTIVES • ECONOMICAL • Commercial product life • R&D budget • Investment budget • Objective unit cost, etc… • TECHNICAL • Key functions • Qualitative level objective : high / middle / low end • Main options • Level of certain performances • Constraints

  9. FUNCTION TYPES • Principal • service or use, appreciation • Secondary • service or use,appreciation • Constraint • environment, legal, rules, regulations

  10. C.D.C.F. = Functional specification Document to define its needs - if a criteria may be defined by another criteria, it becomes a function - several criteria are often needed to define a function

  11. Importance of functions • K coefficient • 1 = wishful • 2 = useful • 3 = important • 4 = very important • 5 = vital

  12. Function flexibility • F coefficient • Flexibility class

  13. 2- Various analysis methods : “RESEAU”, “SAFE”, “FAST”

  14.  METHOD     « RESEAU » FUNCT IONS PRINCIPAL SECONDARYCONSTRAINT Recherche Intuitive Examen de l ’environnement Sequential analysis of functional elements Examen des efforts et des mouvements Utilisation des normes et des règlements Analyse d’un produit de référence

  15. Interest of « recherche intuitive » • Good for brainstorming conditions • Creates favourable situations • Allows debates about ideas • Introduces to other methods

  16. « Examen de l ’environnement » Identification of external elements Description and identification of boundaries Search for adaptation functions Search for interaction functions Limite de l ’environnement Fonction d ’adaptation Element interacteur Produit Fonction d ’interaction

  17. « S.A.F.E. » METHOD • Analysis of product life cycles • SEQUENTIAL • ANALYSIS • FUNCTIONAL • ELEMENTS

  18. S.A.F.E. : intermediate sequences • Not to omit sequences not directly related to service functions such as: • packing • storage • transportation • unpacking • maintenance • recycling

  19. S.A.F.E. : search for functions • To identify functions related to each sequence To have a low volume To move the aspirator To grasp the aspirator To look for the aspirator To be easy to move To be easy to grasp To be easy to identify

  20. Interest of « examen des mouvements et des efforts » • This analysis allows to determine two kinds of functions : • active : ex : displacement • passive : ex : reaction to load • with a certain characteristic : • normal • occasional • exceptional • with an origin • internal to product • external to product

  21. Characteristic of a function - product : train elbow-rest = normal characteristic : Ppssenger’s elbow i.e. around 5 kgs = occasionnal characteristic : passenger’s weight i.e. around 80 kgs

  22. « Analyse d’un produit de référence » • Products : similar, analog or competitive

  23. Patents • « Institut National de la Propriété Industrielle » • Search in published documents • Patent documents • Investigation of patents • national • european • international

  24. F.A.S.T. Method • Charles W.Bitheway 1964 • Functional • Analysis • System • Technique

  25. Interest of F.A.S.T. method • To organize the functions • To verify the logics and control their relations • To check exhaustivity • To generate a creativity atmosphere

  26. Methodology • Isolate general functions • Put them on a map • Position them in order to answer « why », « how » & « when »

  27. F.A.S.T. Graph To use a power source How ? To action a system To have low noise When ? To suck in the dust To filter the recycled air To remove the dust Why ? To clean the room = critical path

  28. 3- “FMEA” applications

  29. F.M.E.A. method • = failure mode and effects analysis • To evaluate the effects of each failure mode and consequences on system functions • Safety / reliability concepts

  30. F.M.E.A. within the automotive industry : gravity • G Index: failure: client perception • 1 : minor : without any consequence • 2-3 : without any effect on performance : slight trouble • 4-5 : with forward indication : trouble • 6-7 : visible damage : serious trouble • 8 : with forward indication : deep trouble and high maintenance costs • 9 : without forward indication : same effect • 10 : same but with safety issues

  31. F.M.E.A. within the automotive industry : frequency • F index : probability of event • 1 : 0 à 3 / 100 000 • 2 : 3 à 10 / 100 000 • 3 : 1 à 3 / 10 000 • 4 : 3 / 10 000 à 10 / 10 000 • 5 : 1 / 1 000 à 3 / 1 000 • 6 : 3 / 1 000 à 10 / 1 000 • 7 : 1 / 100 à 3 / 100 • 8 : 3 / 100 à 10 / 100 • 9 : 10 / 100 à 30 / 100 • 10 : 30 / 100 à 100 / 100

  32. F.M.E.A. within the automotive industry : detection • D index : probability of no detection • 1 : 0 à 2 % • 2 : 2 à 12 % • 3 : 12 à 22 % • 4 : 22 à 32 % • 5 : 32 à 42 % • 6 : 42 à 52 % • 7 : 52 à 62 % • 8 : 62 à 72 % • 9 : 72 à 82 % • 10 : 82 à 100 %

  33. F.M.E.A. within the automotive industry : criticity • IPR = G x F x D • Risk priority index • IPR greater than 100 • = to define an action plan • = persons in charge • = delivery times

  34. 4- Reliability and safety of systems

  35. Compromise reliability / safety • Armament system : • - premature closing: P1 de O,O1 • - impossible closing: P2 de O,O2 To compare reliability / safety of each of the 3 systems ?

  36. 5- Value analysis techniques

  37. THANK YOU FOR YOUR INTEREST !!!!!

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