Preface |
|
ix | |
Acknowledgments |
|
xi | |
1 New product development process |
|
1 | (18) |
|
|
1 | (1) |
|
1.2 Phases of new product development |
|
|
2 | (9) |
|
1.2.1 Phase I—concept planning |
|
|
3 | (1) |
|
1.2.2 Phase II—product planning |
|
|
4 | (2) |
|
1.2.3 Phase III—product engineering design and verification |
|
|
6 | (3) |
|
1.2.4 Phase IV—process engineering |
|
|
9 | (1) |
|
1.2.5 Phase V—manufacturing validation and ramp-up |
|
|
10 | (1) |
|
1.3 Patterns of new product development |
|
|
11 | (2) |
|
1.4 New product development and Design for Six Sigma |
|
|
13 | (4) |
|
1.4.1 DfSS core objectives |
|
|
13 | (2) |
|
|
15 | (1) |
|
|
16 | (1) |
|
|
17 | (1) |
|
|
17 | (2) |
2 Statistical background for engineering design |
|
19 | (27) |
|
|
19 | (5) |
|
2.2 Statistical distributions |
|
|
24 | (10) |
|
2.2.1 Normal distribution |
|
|
24 | (3) |
|
2.2.2 Lognormal distribution |
|
|
27 | (3) |
|
2.2.3 Weibull distribution |
|
|
30 | (2) |
|
2.2.4 Exponential distribution |
|
|
32 | (2) |
|
|
34 | (9) |
|
2.3.1 Probability plotting—lognormal distribution |
|
|
35 | (1) |
|
2.3.2 Probability plotting—normal distribution |
|
|
36 | (1) |
|
2.3.3 Probability plotting—Weibull distribution |
|
|
37 | (2) |
|
2.3.4 Probability plotting—exponential distribution |
|
|
39 | (1) |
|
2.3.5 Probability plotting with confidence limits |
|
|
40 | (3) |
|
|
43 | (1) |
|
|
44 | (2) |
3 Introduction to variation in engineering design |
|
46 | (17) |
|
3.1 Variation in engineering design |
|
|
46 | (1) |
|
|
47 | (1) |
|
3.3 Protecting designs against variation |
|
|
48 | (3) |
|
3.4 Estimates of means and variances of functions of several variables |
|
|
51 | (8) |
|
|
59 | (1) |
|
|
59 | (1) |
|
|
60 | (1) |
|
|
61 | (2) |
4 Monte Carlo simulation |
|
63 | (13) |
|
4.1 Determining variation of the inputs |
|
|
63 | (1) |
|
4.2 Random number generators |
|
|
64 | (2) |
|
|
66 | (4) |
|
|
70 | (4) |
|
|
74 | (1) |
|
|
75 | (1) |
5 Modeling variation of complex systems |
|
76 | (22) |
|
5.1 Approximating the mean, bias, and variance |
|
|
77 | (4) |
|
5.2 Estimating the parameters of non-normal distributions |
|
|
81 | (3) |
|
5.3 Limitations of first-order Taylor series approximation for variance |
|
|
84 | (7) |
|
5.4 Effect of non-normal input distributions |
|
|
91 | (2) |
|
5.5 Nonconstant input standard deviation |
|
|
93 | (1) |
|
|
93 | (2) |
|
|
95 | (3) |
6 Desirability |
|
98 | (25) |
|
|
98 | (1) |
|
6.2 Requirements and scorecards |
|
|
99 | (4) |
|
6.2.1 Types of requirements |
|
|
100 | (1) |
|
|
101 | (2) |
|
6.3 Desirability—single requirement |
|
|
103 | (6) |
|
6.3.1 Desirability—one-sided limit |
|
|
104 | (2) |
|
6.3.2 Desirability—two-sided limit |
|
|
106 | (1) |
|
6.3.3 Desirability—nonlinear function |
|
|
107 | (2) |
|
6.4 Desirability—multiple requirements |
|
|
109 | (6) |
|
6.4.1 Maxi-min total desirability index |
|
|
114 | (1) |
|
6.5 Desirability—accounting for variation |
|
|
115 | (3) |
|
6.5.1 Determining desirability—using expected yields |
|
|
115 | (1) |
|
6.5.2 Determining desirability—using non-mean responses |
|
|
116 | (2) |
|
|
118 | (1) |
|
|
118 | (5) |
7 Optimization and sensitivity |
|
123 | (30) |
|
7.1 Optimization procedure |
|
|
123 | (5) |
|
|
128 | (1) |
|
|
129 | (4) |
|
7.4 Sensitivity and cost reduction |
|
|
133 | (16) |
|
7.4.1 Reservoir flow example |
|
|
134 | (1) |
|
7.4.2 Reservoir flow initial solution |
|
|
135 | (1) |
|
7.4.3 Reservoir flow initial solution verification |
|
|
136 | (2) |
|
7.4.4 Reservoir flow optimized with normal horsepower distribution |
|
|
138 | (2) |
|
7.4.5 Reservoir flow optimized with normal horsepower distribution verification |
|
|
140 | (1) |
|
7.4.6 Reservoir flow horsepower variation sensitivity |
|
|
141 | (2) |
|
7.4.7 Reservoir flow horsepower lognormal probability plot |
|
|
143 | (1) |
|
7.4.8 Reservoir flow horsepower Cpk optimization using a lognormal distribution |
|
|
144 | (5) |
|
|
149 | (1) |
|
|
150 | (3) |
8 Modeling system cost and multiple outputs |
|
153 | (17) |
|
8.1 Optimizing for total system cost |
|
|
153 | (5) |
|
|
158 | (6) |
|
|
159 | (1) |
|
8.2.2 Computing nonconformance |
|
|
159 | (5) |
|
|
164 | (2) |
|
|
166 | (1) |
|
|
167 | (3) |
9 Tolerance analysis |
|
170 | (15) |
|
|
170 | (4) |
|
9.2 Tolerance analysis methods |
|
|
174 | (4) |
|
9.2.1 Historical tolerancing |
|
|
174 | (1) |
|
9.2.2 Worst-case tolerancing |
|
|
175 | (1) |
|
9.2.3 Statistical tolerancing |
|
|
175 | (3) |
|
|
178 | (1) |
|
9.4 Drift, shift, and sorting |
|
|
179 | (3) |
|
|
182 | (1) |
|
|
182 | (1) |
|
|
182 | (3) |
10 Empirical model development |
|
185 | (17) |
|
|
185 | (8) |
|
|
193 | (7) |
|
10.2.1 Central composite designs |
|
|
194 | (6) |
|
|
200 | (1) |
|
|
200 | (1) |
|
|
201 | (1) |
11 Binary logistic regression |
|
202 | (23) |
|
|
202 | (3) |
|
11.2 Binary logistic regression |
|
|
205 | (12) |
|
11.2.1 Types of logistic regression |
|
|
205 | (1) |
|
11.2.2 Binary versus ordinary least squares regression |
|
|
206 | (2) |
|
11.2.3 Binary logistic regression and the logit model |
|
|
208 | (3) |
|
11.2.4 Binary logistic regression with multiple predictors |
|
|
211 | (1) |
|
11.2.5 Binary logistic regression and sample size planning |
|
|
211 | (1) |
|
11.2.6 Binary logistic regression fuel door example |
|
|
212 | (1) |
|
11.2.7 Binary logistic regression—significant binary input |
|
|
213 | (1) |
|
11.2.8 Binary logistic regression—nonsignificant binary input |
|
|
214 | (1) |
|
11.2.9 Binary logistic regression—continuous input |
|
|
214 | (1) |
|
11.2.10 Binary logistic regression—multiple inputs |
|
|
215 | (2) |
|
11.3 Logistic regression and customer loss functions |
|
|
217 | (3) |
|
11.4 Loss function with maximum (or minimum) response |
|
|
220 | (3) |
|
|
223 | (1) |
|
|
223 | (2) |
12 Verification and validation |
|
225 | (14) |
|
|
225 | (3) |
|
12.2 Engineering model V&V |
|
|
228 | (2) |
|
12.3 Design verification methods and tools |
|
|
230 | (3) |
|
12.3.1 Design verification reviews |
|
|
230 | (1) |
|
12.3.2 Virtual prototypes and simulation |
|
|
231 | (1) |
|
12.3.3 Physical prototypes and early production builds |
|
|
232 | (1) |
|
12.3.4 Confirmation testing comparing alternatives |
|
|
232 | (1) |
|
12.3.5 Confirmation tests comparing the design to acceptance criteria |
|
|
233 | (1) |
|
12.4 Process validation procedure |
|
|
233 | (5) |
|
|
238 | (1) |
References |
|
239 | (3) |
Bibliography |
|
242 | (4) |
Answers to selected exercises |
|
246 | (5) |
Index |
|
251 | |