An Integrated Management System of Product Failure Information on Design and Production Stage

Design and Integration Seminar 2005 Pre-workshop 15:30～16:50 2005/11/21 at Osaka University An Integrated Management System of Product Failure Information on Design and Production Stage Tsuyoshi Koga and Kazuhiro Aoyama University of Tokyo School of Engineering

Background Increasing Management System of Failure Information is highly desired • Eradication of product failure is one of the dreams of manufacture. • Product failures are causing loss costs. • on design stage • on production stage • even if products were in the market • Product failures are increasing. Production Failure (Press operation) Burr by cutting Spread burr Press Machine Operator ！ Design failure (Overturn check) Forming Operation Failure in market (Automotive Recalls) Number of Recalls

Problems PLM (Product Lifecycle Management) PDM (Product Data Management) EAI (Enterprise Application Integration) Process Shortenings Test Less Development Lack of Desk Examination and Validation QC process chart Check List Failure Cases Design / Process FMEA Sheet Design Don'ts Representation, Access and Share of Failure Information using Information System of Design and Production is required Today, Information Access and Share between Engineers have been achieved by Information System of Design and Production. However, QCD (Quality, Cost, Delivery) Requirement is getting more and more inclement. Efforts for Failure Reduction Huge number of Documents Kaizen- activities Problems are still remain Bottom-up improvement Very hard to be referred Lateral Spread is difficult Japanese company is very good at Isolated Dried Rag

Purposes Goal Realization of Representation, Access and Share of Failure Information using Information System of Design and Production Vehicle Recalls that has causality across Design and Production (45%) To achieve this goal, Detailed purposes (1) Model of Failure Causality across Product and Production • Today nearly half of failures have causality between design and • production. • Integration of Product Failure Model and Production Failure Model • is required. Low Cost High Cost (2) Multi-stage Design Method to reduce failures Trouble Cost • Decisions of early design stage have huge impacts on • detailed design stage. • Failure factors should be eliminated from initial design stage. Design Production Operation

Overview Computer Integrated Product and Production Information system that provides cross-sectional failure information from initial design stage. Design Review Room (1) Product Behavior (2) Production Process (3) IPPF Model (Integrated Product-Production- Failure Model) Required Behavior Product Info. Manufactured Quality Production Process Production Engineer B Designer A Designer B Production Engineer B Production engineers can know why this component is required and how it is going to work on entire product life cycle. Designers can know how it is going to make and what is going on in the production process. They can share in this room the causality of product failure between product and production.

Scenario Product Design Production Design Model of Failure Causality across Product and Production Failure Model Formulation of Design Process to reduce product failure Design Process Failure reduction method on Product Design Failure Reduction method on Production Process Design Cross-Sectional Failure Database Acquirement of Cross-Sectional Failure by Database Prototype System Conclusion

Definition of Product Failure Required Behavior is not achieved Unexpected / Hazardous Behavior is generated Usually, product failure is defined as loss of product functions. (JIS Z 8115) Required Behavior Product Behavior Unified-description-model of product function does not exist. [Tomiyama 1997] （a）（b） So I focused onProduct Behavior. （Product function = subjective recognition) Definition of Product Failure （a） Loss of Required Behavior or （b） Generation of unexpected (Hazardous) Behavior

An example actual failure case ②Garage Operation ⑤Sudden Acceleration ⑥Injury Accident ①Air Contamination ①Escape into The Market ③Load Increment ④Engine Speed will increase ②Cavitations Causes ！ Stall Prevention Control Process Change Of Chassis Assembling ①PS (Power Steering) Oil contains air by the process change of Chassis Assembling. ②When the user operated this automobile in a garage, Cavitations in PS Pump is generated. ③Cavitations cause incrementation of Rotation Load. Results Sudden Acceleration Engineers must realize and prevent these failures ④Rotating Speed of Engine will increase by stall prevention control ⑤Suddenly automobile will accelerate at garage operation Failures can be modeled by Causal Chains between causes and results ⑥Hazardous situation (e.g. Injury Accident) could happen Production Process Steering & Suspension Assembling Transfer Machine Product and Required Behavior Chassis Assembling 1 Chassis Assembling 2

Manu- factured Quality Product Structure/ Behavior Model of Failure Mechanism Failure Mechanism Manufactured Quality Generation Quality Propagation Chain of Scenes Causal Chain Inside Product Production Process Required Behavior State Quality Product Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Computer comprehensive Model is required →Petri-Net Required Behavior Model Manufactured Product Production Process Model Product Information Press line

Manufactured Quality Generation Quality Propagation Manu- factured Quality Production Process Quality ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Manufactured Product Production Process Model Production process model Failure Mechanism Manufactured Quality Generation Quality Propagation Chain of Scenes Causal Chain Inside Product Manu- factured Quality Production Process Required Behavior Product Structure/ Behavior State Quality Product Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Required Behavior Model Manufactured Product Production Process Model Product Information

Model of Production Process Definition of Production Process Definition of Each Element Name Symbol Definition ◇Operation can act on Manufactured Product and change its manufactured state 　◇Manufacturing Product can be modeled as Manufactured Entities and Interfaces 　◇Production Process can be represented as sequences of operations Manufactured Entity Element of Manufactured Product Interface between Manufactured Entities Assembling Connection between Entities Attribute of Entities and Interfaces generated by Production Process Attribute Production Process Quality of Manufactured Product in Production Process (Place) Manufactured State Intermediate Part (Output) Manufactured Product Manufactured State Change Change of Quality State (Transition) Manu- factured Entity Manu- factured State Manu- factured State Change Manu- factured State Operation Intermediate Part or Assembly in Production Process (Place) Intermediate Part Condition Operation generates Attribute of Manufactured Product (Transiton) Intermediate Part (Input) Operation Attribute Value of Attribute Value of Attribute

Description of Failure in Production Stage 3 types of production failure (1) Defect of Product (e.g. Additive Defect) (2) Defect of Operation (e.g. Miss Operation) (3) Causal Chain inside Product 2 Types of Operations (1) Assembling Operation: Generate Interface Quality (2) Manufacturing Operation: Generate Entity Quality Symbol Correspondence between Entity and Intermediate Product Test Arc Assembling Operation Manufactured Entity A Intermediate Product AB Separated Connect Operation ab Intermediate Product B weld Manufactured Entity B Causal Chain inside Manufacturing Product Intermediate Product A Manufactured Entity Quality State 1 Quality State2 State Change Factor of Product and Production Process Product Production Process plastic strain Uneven Material f(a,b,c) Attribute Value b Value a Press Formed Completed hood panel wrinkle Forming press Forming press Manufactured Entity Quality State 3 Wrinkled wrinkle Sheet Height 8mm Height 4mm Height<6mm Then true Wrinkle Attribute Value c true false Coil Cut

Causal Chain Inside Product Product Structure/ Behavior Product Behavior ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions Product Information Product structure and behavior model Failure Mechanism Manufactured Quality Generation Quality Propagation Chain of Scenes Causal Chain Inside Product Manu- factured Quality Production Process Required Behavior Product Structure/ Behavior State Quality Product Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Required Behavior Model Manufactured Product Production Process Model Product Information

Model of Product Behavior and Structure 1200 Definition of Product Behavior and Structure Definition of Each Element Behavior of Product Element is represented as network of States and Actions 　◇Product Structure is represented as Design Entity and Interactions 　◇State means the value area of Attribute 　◇Action means the change of Attribute 　◇Product Behavior Token means entity state at given moment Name Symbol Definition Design Entity Element of Product Interactions (Connection, Signal/Material/Energy Flow ) between Entities Interaction Between Design Entities Attribute Value of Entity And Interface Attribute <Example of description model> Recognition of area of Attribute Value (Place) State Idle up control Idling Up Idling Engine Attribute Change between States (Transition) Action Revolution Resistance Amplify Air Cont- amination (rpm) 500 Product Behavior Token State of Entity at given moment PS Pump cavitate Rotational Resistance 0.1(N/m) 0.3(N/m) (N/m) 0.1 0.3

Model of Component Failure Arrangement of Power Steering System High Pressured Piping Pump Pump Driving Belt Clamp of High Pressured Piping Component failure can be represented by product model. 　◇ Component state that derives product failure = Failure State. 　◇ Component action that derives product failure = Failure Action. Failure states and actions propagate inside product. Legend Symbol Failure State Failure Action Example Test Arc depressure Line Pressure High Pressure Power Steering Pump Synchronous Arc pressure Strain Unstrain Clamp of High Pressured Piping deteriorate Oil Splash High Pressured Piping Normal leak Rotation Ignition Power Steering Pump Driving Belt Oil attatch

Chain of Scenes Required Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions Required Behavior Model Required behavior model Failure Mechanism Manufactured Quality Generation Quality Propagation Chain of Scenes Causal Chain Inside Product Manu- factured Quality Production Process Required Behavior Product Structure/ Behavior State Quality Product Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Required Behavior Model Manufactured Product Production Process Model Product Information

Model of Required Behavior Definition of Each Element Definition of Required Behavior Name Symbol Definition Required Behavior means the whole Product Behavior that fulfils its function 　　◇Network of Scenes and Events 　　◇Scenes and events have environmental attributes. 　　◇Required Behavior Token means the whole Product State at given moment Required Whole Product State (Place) Scene Required Whole Product Action (Transition) Event Unintended or Hazardous Scene (Place) rotate back Hazard Scene sudden accelerate Unintended or Hazardous Event (Transition) Garage Operation Fully Turning Injury Accident Hazard Event full rotate Environmental Attribute Physical Attribute dust / splash / snow / dirt / torque fluctuations / displacement/twisting...etc. Chemical Attribute brine damage / ozone / ...etc. Operational Attribute operation time, speed, Load / switching time / rotation speed...etc. [Example] Fully Turning full rotate Rotation Speed Average Speed Rotation Torque Time

State Integration between product and production Failure Mechanism Manufactured Quality Generation Quality Propagation Chain of Scenes Causal Chain Inside Product Manu- factured Quality Production Process Required Behavior Product Structure/ Behavior State Quality Product Behavior ・Whole Product Scene ・Whole Product Event ・Environmental Load ・Hazardous Situations and Actions ・Components ・Topological Structure ・Attributes ・Element State ・Element Action ・Interactions ・Production BOM ・Assembling Connection ・Manufactured State ・Manufactured State Change ・Quality Propagation inside Product ・Operation （Worker, Equipment, Condition）・Intermediate Product (Partly-finished Product) ・Quality Propagation Required Behavior Model Manufactured Product Production Process Model Product Information

Mapping between Design State and Manufactured State Dynamic spring Mapping Function Static spring Hysteresis Design State must be achieved by Manufactured State 　◇Designers assign Entity State in order to realize Required Behavior 　◇Production Engineers grasp its quality as Manufactured State 　◇Mapping Function of functional attributes and manufactured attributes can be defined. Rubber Insulation Rubber Insulation Manufactured State Dynamic spring Sulfur mixing ratio Color Static spring Designed State Hysteresis Manufactured Attributes Functional Attributes Translated Attribute Design Engineer Production Engineer Mapping between Design State and Manufactured State Correspondence between design attributes and manufactured attributes

Example of Failure Model This model is Failure Causality across Product and Production Failure Case ②Garage Operation ⑤Sudden Acceleration ⑥Injury Accident Steering & Suspension Assembling Transfer Machine Product and Required Behavior ①Air Contamination ①Escape into The Market ③Load Increment ④Rotation Speed will increase ②Cavitations Chassis Assembling 1 Chassis Assembling 2 Failure model description Required Behavior Production Process Product Structure/ Behavior Manu- factured Quality Release Valve idle up control Idling up Close Engine Injury Accident Air bleed sudden accelerate No Air Air Containing Air Containing Resistance Amplify boil air bleed PS Pump PS Pump Fully Turning cavitate full rotate Oil Filled more than 5% Rate of Air Content Rate of Air Content 0.3(N/m) 3% 9% Garage Operation

Design method for Failure Reduction Manu- factured Quality Required Behavior Product Structure/ Behavior Manu- factured Quality Production Process Product Structure/ Behavior Design Method 1：Input Required Behavior and output Interactions Propose Interaction Design Algorithm Design Method 2：Mapping between Design State and Manufactured Quality Concrete Example Design Method 3：Input Required Quality and output Sequence of Operations Propose Quality Design Algorithm of Production Process Mechanism of Failure Production Process Product Behavior State Quality Design Method Required Behavior Design Method 1 Design Method 2 Design Method 3

Design Process Requirement Design Structure/ Behavior Design Quality Design Production Process Design Conceptual Requirement Conceptual Structure Conceptual Quality Conceptual Process c) Quality Assignment e) Quality Embodiment a) Product design b) Behavior Generation d) State Generation f) Quality Generation 1)Requirement Decomposition 2)Structure Decomposition 3)M-BOM Decomposition 4)Process Decomposition Detailed Quality Detailed Requirement Detailed Process Detailed Structure Mapping Decomposition

Scenario Product Design Production Design Model of Failure Causality across Product and Production Failure Model Formulation of Design Process to reduce product failure Design Process A product design method to reduce failure Failure Reduction method on Production Process Design Cross-Sectional Failure Database Acquirement of Cross-Sectional Failure by Database Prototype System Conclusion

Failure Reduction in Product Design Stage Specifications Design Method that can prevent the loss of Required Behavior or generation of Unintended (Hazardous) Behavior from early design stage is required. Scenes (Product Behavior) ? ? A Product ? ? A Customer What is Failure in Product Design Stage? 　◇Loss of Required Behavior 　◇Generation of Unintended (Hazardous) Behavior What is Product Design? 　◇Translation from a functional concept (spec concept) into a solution concept 　◇Behavior Concept is required to consider product failure Product Design in this research 　◇The output process of Product Components and Interactions by the input of Required Behavior The Design Concept of GDT [Yoshikawa 1987] Functional Space Attribute (Entity) Space A Customer A Designer Product Attributes The Design Concept of this Research Product Behavior Space Components and Interaction Space Product Components and Interactions A Designer

Indicator of Failure: Performance close Charging Empty Stapled release open fire charge close Charged Ready open push & fire close Charging Empty open fire fire fire Unintended Scenes and Events Lack of Scenes and Events charge －－ Stapled close push Miss Fire Charged Ready open Xsa Lack of Scenes Xs Unintended Scenes Miss Fire Xma Lack of Events Stapled Empty Xm Unintended Events Empty Stapled charge release fire Ready Ready Miss Fire Ready Required Behavior G1 Calculated Behavior G2 Comparison between G1 and G2 Definition of Performance Value of Required Behavior ＝ Performance

Product Behavior Design Housing Housing Opened push Magazine Unit Magazine Unit fire (A) Component Behavior (B) Interactions (Empty, Opened) (Empty, Closed) close Charging Housing Empty release Calculate open charge Stapled (Empty, Pushed) close Magazine Unit Charged push Ready (Charged, Opened) (Charged, Closed) open (D) Product Behavior (C) Product Information release release open open Opened Opened Closed Closed Pushed Pushed push close push close charge charge Charged Charged Empty Empty fire fire ◆Product Behavior design = Component design + Interaction design 　◇Product Information consists of Component Behavior and Interactions between them. 　◇Product Information determines Product Behavior. 　◇From comparison between Required Behavior and Product Behavior, performance can be calculated. ＋ =

Interaction design method (G) Evaluation Result Feed Back Learning • Performance: 91.3 • Feasibility: 56% • Classification: Xa • Absent Action: {E1} • Superfluous Action: {E2} (H) Comparison between Required Behavior Generate Interface Structure (B) (F) (C) Product Information (E) Product Behavior close Charging Empty Stapled release open E1 (D) E2 charge charge push&fire Calculate Behavior close Charged Ready open From iteration cycles, system outputs Interactions that maximize Performance. release open Opened Closed Pushed push close charge Charged Empty Housing fire Magazine Unit ◆ Especially, interaction design is difficult. ◆Therefore, computational design assist method is required. (A) Importance of Interactions Opened open close Closed release push Pushed Charged charge fire Empty

Design Example of Auto-Breaker Required Behavior Product Information Calculated Product Behavior Input: Hazard Scene, Component failure, Required Behavior Output: Product Information that satisfies Required Behavior and does not involve product failure Shape Attribute

Scenario Product Design Production Design Model of Failure Causality across Product and Production Failure Model Formulation of Design Process to reduce product failure Design Process Failure reduction method on Product Design A design method of production process to reduce the failure Cross-Sectional Failure Database Acquirement of Cross-Sectional Failure by Database Prototype System Conclusion

Reduction of production failure Design Method of Production Process that satisfy Required Quality is required. ◆What is quality problem in production? 　◇Generation of quality that derives Product Failure ◆What is production? 　◇Generation process of product attribute ◆What is production process design? 　◇Operation design 　◇Sequence design of Operations Production Process of Vehicle Machining Forging TRSM Assembling Engine Assembling Melting STRG/SUSP Assembling Melting Transfer Coating Die-casting Die Chassis Assembling Assembling 2 Finished Car Assembling Coating Cutting Press Body Assembling [Hitomi 90]

Model of Production Process Operation 2 Operation 4 Model of Production Process ◆Model of Production Process 　◇Production Process is represented as a sequence of Operations 　◇Operation can change Quality State of Manufactured Entity ◆Behavior of Production Process 　◇From Production Process model, computer can calculate the behavior of production process 　◇Marking5 means Quality Problem 　◇Production Scenario of Quality Problem can be calculated 　◇This model can be simulated by probability of Quality Change and actual performance of Operations 　　１．Per cent defectives 　　２．Contribution List of Failure Factors Intermediate Product 3 Quality Change Manufactured Entity Operation 4 Quality State 1 Quality State 2 Operation 3 Intermediate Product 2 Operation 2 Quality Change Operation 1 Explanatory note Intermediate Product 1 Synchronous Arc Quality Problem Computational calculation Space of Quality State Explanatory note Marking1 Marking Intermediate Product 1 Quality State 1 Firing Sequence Operation 1 Operation 2 Marking3 Marking2 Intermediate Product 2 Intermediate Product 2 Quality State 1 Quality State 2 Operation 4 Operation ３ Operation 4 Operation 3 Marking5 Marking4 Intermediate Product 3 Quality State 1 Intermediate Product 3 Quality State 2

Design Method of Production Quality Scenario of Quality Generation Closed Filled No Air Opened Filled No Air Opened Filled Containing Opened Empty Closed Filled Containing Closed Filled Containing Closed Empty Assembled PS Oil ◆Procedures STEP1 Calculate the Space of Quality State Change by combination of possible Operations STEP2 Select required Quality State and Scenario of Quality Generation STEP3 Output Sequence of Operations STEP2 Select final Quality State and Scenario of Quality Generation ◆Hierarchy Model of Quality Quality State of Assembly = Combination of Quality States of Components required Quality State PS Pump ASSY STEP1 Calculate Space of Quality State Change STEP3 Output Sequence of Operations Closed close Opened Valve close No Air Air Containing boil bleed air PS Pump Oil Filled Oil Empty fill oil influx

Design Example (Auto-Breaker) • Design problem • How to produce this Contact ASSY that does not involve qualitical problem Arrangement of Contact ASSY Real Shape Contact ASSY Manufacturing BOM of Contact ASSY

1st Step: List up Conceivable Operations Three operations ①Brazing Disconnected connect by braze Connected ②Calk Disconnected Connected connect by caulk ③Form press Shape Formed Produced bend by form press

2nd Step: List up Conceivable failures Two possible failures of operations ④Curve by brazing Curved Shape Formed curve by braze ⑤Misalign by forming press Produced Misaligned misalign by form press

⑤ ② ① ③ ④ ② ① ③ ④ ⑤ 3rd Step: Calculate combined network （A) Product Structure Combined Structure/Operation/Failures （B) Conceivable Operations （C) Conceivable Failures

凡例 Failure Quality Normal Quality Specify the scenario that does not involve failure quality 4th Step: Calculate Space of Quality State Reachable Tree

Caulked Pressed Brazed Contact Contact Plate Result • Output is Production Process • Output means that failure reduction is achieved by the production process of brazing, form press and caulk

Result of Auto-Breaker Design Mapping Structure/ Behavior Design Requirement Design Quality Design Production Process Design <b>Conceptual Structure <a>Conceptual Requirement <c>Conceptual Quality <d>Conceptual Production Decomposition <f>Detailed Structure <g>Detailed Quality <e>Detailed Requirement <h>Detailed Production

Forming Brazing Brazing Forming Impact Analysis of Design Change (Production Process) Before Change Product Behavior Product Structure Quality Information Production Process ① ② After Change Product Behavior Product Structure Quality Information Production Process ② ① If production engineer want to reverse two operations, forming and brazing, Generated quality is changed and product state is changed. So product failure can be detected.

connect Contact ASSY Connected disconnect Disconnected interrupt down up interrupt Lever ASSY Miss-trip Shape Formed Pressed Contact Plate bend disconnect Mounted Miss Trip Contact solder dust Connected form press mount Trip Produced Lever ASSY Trip Fixed Contact solder dust generate interrupt solder Produced Contact Plate form press Contact Melt arc generate Part Cause Result All Knowledge Repository based on PPF Model Product-Production- Failure (PPF) Information Model Provide Unified Terms and Expanded Search Provide Causal Knowledge Provide element vocabulary Causal Relationship Each Element Unit Entity or Operation Contact Abstract Taxonomy Database Causal Database Unit Element Database Concrete

Prototype System Product Structure / Behavior Required Behavior Quality Information of Manufacturing Product Production Process Architecture of information on proto-type system

Demonstration Movies Movie1: Product-Production-Failure (PPF) Information Model Movie2: Simulation of Production and Behavior Movie3: Acquirement of Cross-Sectional Failure

Conclusion • Model of Failure Causality across Product and Production is proposed. • Cross sectional knowledge can be shared • Product failure and behavior • Quality change in manufacturing process • Design method to reduce failures by step-by-step decomposition is proposed. • Reduction of product failure from early design stage • Development shortenings

That's All. Thank You!

An Integrated Management System of Product Failure Information on Design and Production Stage