#1The Sixth Japan TRIZ Symposium 2010 TRIZ for Managers - Approach and Management using a Scientific Methods - Scientific methods (QFD, TRIZ, Taguchi method, etc.) are tools for gaining, operation itself and management itself! MOST, LLC President 2010. 9. 10 Kazuya Yamaguchi Translated by Yoshihisa Konishi#2Company Profile About MOST, LLC A group where retired employees of Panasonic and Panasonic Communications Co., Ltd., who had mastered scientific methods (general-purpose techniques such as QFD, TRIZ, Taguchi method, multivariate analysis, sales analysis, etc.) and were active at the company-wide work restructuring, have gathered together. The name MOST was denominated with the following meaning: You can get the MOST performance by MOST (Management Of Scientific Tool) with MOST (MOST, LLC). MOST, LLC 1-19-11 Tobitake, Umimachi, Kasuyagun, Fukuoka President: Kazuya Yamaguchi E-mail: [email protected] TEL, FAX 092-932-9701#3Biography of Kazuya Yamaguchi, President of MOST, LLC 1970.3 1970.4 Graduated Communication Engineering Dept., School of Engineering, Kyushu University Joined Kyushu Matsushita Electric Industrial Co., Ltd engaged in product development served as technical section chief and manager • engaged in company-wide work reconstruction Kyushu Matsushita Electric Industrial Co., Ltd General Manager, Development Process Innovation Department Panasonic Communications Co., Ltd. Deputy General Manager, Management Quality Promotion Department (Japan Quality Award, development process innovation, quality innovation, back-office section innovation, factory innovation), (2007.8.31 age-limit retirement) Currently President of MOST, LLC (Established 2007. 9. 3) Part time lecturer at Ritsumeikan University Postgraduate school (Quality Management) Part time lecturer at Yamaguchi University (Leading edge in Development Process) Part time lecturer at Kyusyu University (Management Quality Innovation)#4Lecture Contents I. The figure which a company activity aims at 1) The present conditions in development of products and things, and the direction that we should aim at 2) Relation between JQA(Japan Quality Award) thought and application of scientific technique II. Trans-Disciplinary Fundamental Technologies 1) What is needed to accomplish the mission of company activity 2) What is QFD(Quality Function Deployment)! 3) What is TRIZ! 4) What is Quality Engineering (Taguchi Method)! III. Summary 1) Creative problem solving process and scientific methods 2) Difference between scientific method utilization and common management! 3) What is TRIZ for managers!#5I. The figure which a company activity aims at 1) The present conditions in development of products and things, and the direction that we should aim at 2) Relation between JQA(Japan Quality Award) thought and application of scientific technique#61-1) The present conditions in development of products and things Inefficient activity of own way No management Nonscientific contempt A way of thinking to assume that we are good at the level that we had (plan, quality, cost, delivery date, function) Waste of money, Waste of time, Lose competitive advantage We lose the trust of customers Tough management situation#71-2) Direction that we should aim at " "Approach and Management" With rational scientific technical method With future prediction and development of products Good, early and cheaply We have to realize necessarily, logically and scientifically Products which are superior to other companies Products development of good cost performance Lighter, more compact facilities 1/10 facility development We need a management who can say this#8How will QCD be improved when we use scientific technical methods? Conventional development technique management 1. Left to individuals We think to have fully drawn abilities of engineers 2. Management is difficult We can show only power of 30% 3. Without using the brain • Scientific technical method utilizing management 1. Tool is good 2. Technical argument 3. Argument by many We can show power of 130% We can draw abilities of engineers to the maximum Management means to draw abilities of engineers to the maximum Increasing sales and profit by strengthening product competitiveness#9Assessment standard of JQA(Japan Quality Award) JQA 1. Direction to aim at POV: Customer/Competition/Reform Result: Excellent achievement MB Award in US President Regan Scientific method 2. Basic idea (The common sense of values that an organization should have) 1) Basic thought (4 elements) Create and provide customer value (1) A customer-oriented The formation and display of the so way of thinking far few "original ability” that the other organization does not have (4) Harmony with society (2) Original ability (3) Employee serious Contribution to society consideration Harmony with social value Provide places and environment for employees to exercise their autonomy and creativity 2) Decision-making by value premise Value premise management from “ideal world” and “desirability" Disapprove of fact premise management Explore the ideal world to a great deal We will utilize QFD and clarify an aim Realizable with QFD, TRIZ and Taguchi method Managers have to regard these methods as management tools Thought is same as TRIZ and Taguchi method#10II. Trans-Disciplinary Fundamental Technologies "thinking from the standpoint of a manager" 1. Necessity to fulfill mission of company activity 2. What is QFD(Quality Function Deployment)! 3. What is TRIZ! 4. What is Taguchi Method!#111. What are company activities and manager's tasks Steps for product creation at companies Product creation = Requested quality elaborating activity = Intellectual creation activity 1. Marketing Product plan 2. Research and Development 3. Product development and design 4. Fabricating method development Factory 5. Sales (Market) Service Surveying the market and decide what kind of product to make In what parts structure to create the product In what specification to create the product In what facility / condition to create the product Are the customers satisfied? Producing excellent achievements and results ... responsibility of the manager also#121-2) What to study! What to make study! Essentials for products/things creation Traditional approach 1. Expertise and traditional quality control techniques only All-purpose technologies where momentum gathered for activities after 1990 To be Added to the traditional: ceramic technology, electronics, information engineering, communication engineering, mechanical engineering, applied chemistry, physics, aeronautical engineering, electric engineering, etc. 7 tools for QC, TQM, FMEA, FTA, etc. Supports intellectual creativity and problem solving is easily achievable The most important processes are QFD, TRIZ and Taguchi method 2. Development process technology (world's highest all-purpose Managers need paradigm shifts to management technologies) Besides, combined use of IT, etc. is also required#131-3) Product creation oriented Company activity (production cycle) and Development process technology Company activity (production cycle) Marketing Effective Development process technology QFD QFD, TRIZ R & D Product development Fabricating method development Production Verification Sales After-the-sales service TRIZ, Taguchi Method TRIZ, Taguchi Method Taguchi Method Taguchi Method QFD ..... QFD Quality Engineering = Taguchi Method in Japan oversees#14II. Trans-Disciplinary Fundamental Technologies 1. Necessity to fulfill mission of company activity 2. What is QFD(Quality Function Deployment)! 3. What is TRIZ! 4. What is Taguchi Method!#152-1) What is QFD? (Quality Function Deployment) The task of business management or manager begins with accurately understanding the customer's request Method to accurately understand the customer's request The best way to create salable products at various discussions including Product planning stage reflecting matters (quality) requested by customers in product creation Goal clarification Task clarification Action item clarification You may probably think that such things are naturally performed ... ... but, actually, they aren't performed in most cases#162-2) What is QFD? (Quality Function Deployment) A very simple binary sheet) (1) How does the customer like? request Customer 1 quality Required 2 Quality characteristics 3 (2) What should be considered technically for the customer request? 4 Planned quality Important degree (3), (4) What kind of characterization will make the customer happy? (5) How should the specification be to satisfy the customer? 5 Design quality Important! Don't assess the feasibility here#17What is QFD? (Summary) A method for clarifying what technical realization would ensure the qualities that the customers request and make them happy complying with their requests • A method that clarifies the design quality (objective) thereafter Feature Enables investigation without leaks The best way to create salable products reflecting the matters (quality) requested by customers in product creation at various considerations including the product planning stage First, there is QFD in any operation (including R&D) Concrete grounds for realization of technical problems is in TRIZ!#18II. Trans-Disciplinary Fundamental Technologies 1. Necessity to fulfill mission of company activity 2. What is QFD(Quality Function Deployment)! 3. What is TRIZ! 4. What is Taguchi Method!#193-1) A method that supports thinking to enable easy creation of only-one number-one products What is TRIZ? TRIZ/TIPS: (Russian) Tеoрия Решения Изобретательских Задач (English) Theory of Inventive Problem Solving Enables structure determination of a perfect system that is good in QCD The basic of R&D#203-2) What is TRIZ? A tool that supports to easily generate all the ideas for solving difficult technical problems by thinking based on the human thought pattern at the research / development / design stages A tool that supports creativity 1) Investigated and analyzed 2.5M past patents, . • Patents are the thinking agglomerate of resourceful persons of all mankind 2) Systemized patents, and Easily to utilize • Gives hints • Enables logical thinking 3) Created a tool that supports solving difficult technical problems#213-3) How is TRIZ thought pattern! 2.5M patent analysis systematized cases Hints available 99% TRIZ standardizes on sential analogies using exement problem solving case of the past in other fields as hints even for things that seem to be the first case in one's field, etc. and at the same time on pursuing to make the maximum use of ideality and resources (1) Is the current technical problem an unprecedented attempt for mankind? Should be NO (2) Don't you think that there is a solution case of the past in another field that would give you a hint? Should be YES (3) Are the existing resources utilized ideally? Should be NO#223-4) TRIZ is amazing. Why? A way of conventional work Nonscientific contempt • Inefficient activity of own way ● Whack-a-mole R&D activities after one's own style • Solutions within the range which one can think of or recognize TRIZ This is the ultimate level of knowledge management 1. There are all thought patterns of the human in 2,500,000 patents being Person acquiring USA patents is world top-level human 2. It is arranged well Principles, Effects, Prediction 3. Thought aiming at is good The philosophies of "pursuit of ideality", "maximum use of resources" and "contradiction resolution" are explored to a great deal#233-5) TRIZ structure (3 main pillars) 3 Effects generate all ideas for solving Technical alternative 2 Prediction Approaching Ideality Problem Definition QFD 1 Engineering Contradiction Principles important#241 Engineering Contradiction Solving Matrix 39 Worsening Parameters Area 39 Improving Parameters Length Pressure Force Area Length Pressure Force Z. 35,01 14, 16 order Up to 4 Inventive Principle numbers used to solve engineering contradictions are listed according to how frequently they were used in the 2.5M patents#2539 Engineering Contradiction Parameters The same parameters are on the vertical and horizontal axes 1. Weight of moving object 2. Weight of stationary object 3. Length of moving object 4. Length of stationary object 5. Area of moving object 6. Area of stationary object 7. Volume of moving object 8. Volume of stationary object 9. Speed 10. Force (Intensity) 11. Stress or pressure 12. Shape 21. Power 22. Loss of Energy 23. Loss of substance 24. Loss of Information 25. Loss of Time 26. Quantity of substance 27. Reliability 28. Measurement accuracy 29. Manufacturing precision Parameters are described in very versatile termş 30. Object-affected harmful factors 31. Object-generated harmful factors 13. Stability of the object's composition 32. Ease of manufacture 14. Strength 15. Duration of action of moving object 33. Ease of operation 34. Ease of repair 16. Duration of action by stationary object 35. Adaptability or versatility 17. Temperature 18. Illumination intensity 19. Use of energy by moving object 20. Use of energy by stationary object 36. Device complexity 37. Difficulty of detecting and measuring 38. Extent of automation 39. Productivity#26List of 40 Inventive Principles Principles numbers are listed at the intersection of the matrix Principle numbers obtained from the Length vs. Pressure contradiction 35, 01 14, 16 1. Segmentation 2. Extraction 3. Local Quality 4. Asymmetry 5. Consolidation 6. Universality 7. Nesting 8. Counterweight 9. Prior Counteraction 10. Prior Action 11. Cushion in Advance 12. Equipotentiality 13. Do it in Reverse 14. Spheroidality 15. Dynamics 16. Partial or Excessive Action 17. Transition into a New Dimension 18. Mechanical Vibration 19. Periodic Action 20. Continuity of Useful Action 21. Rushing Through 22. Convert Harm into Benefit 23. Feedback 24. Mediator 25. Self-service 26. Copying 27. Dispose 28. Replacement of Mechanical System 29. Pneumatic or Hydraulic 30. Flexible Membranes or Thin Films 31. Porous Material 32. Changing the Color 33. Homogeneity 34. Rejecting and Regenerating Parts 35. Transformation of Properties 36. Phase Transition 37. Thermal Expansion 38. Accelerated Oxidation 39. Inert Environment 40. Composite Materials#27Prediction 2 (Law of Technical Evolution and Standard Solutions) There are laws in • Technical evolution and • Problem solving • Law of technical evolution and Standard solutions#28Overview of "Standard Solutions” in TRIZ Total 127 items A. Completing incomplete "Substance-Fields" B. Detection and measurement problems C. Eliminating harmful effects 1) Modification of an existing substance 2) Modification of field 1 item 12 items 37 items ( 4 items) ( 5 items) (11 items) ( 5 items ) 5) Introduction of a new substance and field ( 3 items) ( 3 items) ( 6 items) 65 items 3) Introduction of a new substance 4) Introduction of a new field 6) Transition to a subsystem 7) Transition to a super-system D. Improving insufficient or excess 1) Modification of an existing substance 2) Modification of field 3) Introduction of a new substance 4)) Introduction of a new field 5) Introduction of a new substance and field 6) Transition to a subsystem 7) Transition to a super-system Field types 13 main types interactions ( 18 items) ( 7 items) (15 items) ( 4 items) (12 items) ( 3 items) ( 6 items) mechanical, optical, thermal, chemical, etc.#293 Effects (Source: TechOptimizer) Engineering database of 5,888 scientific effects and applications 37 items to detect electromagnetic waves or lights: Monitoring X-ray beam alignment Screen for visualization of X-ray images X-ray imaging array Electret dosimeter Optical information recording disc Barkhausen effect Photochromic effect (influence of intensity) Optical memory based on photochromic materials Holographic system Hologram recording material Roentgenoluminescence Principal axes determination in anisotropic crystal Fixing moving image frame Producing image on liquid crystal display Visualization of stress pattern Resonant photodiffractive effect 21 other items#303-6) Feature of ideas by TRIZ utilization Consideration from all angles along TRIZ thought pattern (Idea generation) Image of idea consideration Problem Idea spread through consideration in all directions ⚫ without overlooking and being right on target ⚫ ten to twenty times more ideas compared to conventional ratio Image of classification Gold (Silver) Bronze Idea convergence Putting together as the best concept utilizing all the enormous ideas considering the QCD quality and possibility#313-7) Extract of TRIZ 1. Underlying thought of TRIZ (Goal) We can image the "ideal solution" Thorough pursuit of ideal and evolution of system Maximum use of free resources Minimum introduction of paid resources Result: Seeking an ideal solution, the quality also improves naturally ... same as with Taguchi method 2. Full with hints for solving to ideal solution#323-8) Utilize TRIZ, and develop tactics/strategies for short to long term Even strategies can be developed by idea generation keeping the ideal solution in mind (Ideal situation) Ideal characteristics Tactics Short Trend of evolution Middle term Next generation product Long term Future concept term New product Existing product Strategies Advance patent application Generation#33Management Tool Product 3-9) TRIZ (Summary) Management that supports thinking to enable easy creation of only-one number-one products Supreme knowledge management A tool that supports to easily generate all the ideas for solving difficult technical problems by thinking based on the human thought pattern at the research / development / design stages Within crushingly short time, enables concept (system structure) of a perfect product that excels in ideality and goes ahead of the times Taguchi method#343-10) How to use TRIZ actually? 1. Define voice of customer and the goal we want to create 2. Product plan... what should be possible technically? Product concept (Goal) Research and development ... what should be possible technically? Clarification of goals (The higher the goal, the better) ... QFD Research and Development ... What kind of thing can be technically done? Design ... We want to largely lower component cost TRIZ Schema clarification on the desk (with the brain only) . • Embodiment on the desk (brain only) • Foresee the future (from tactics to strategies) Concrete product concept (Product creation that makes positive impression on customers) Enables structure determination of a perfect system that is good in QCD Taguchi method Products creation tolerant of error conditions#35II. Trans-Disciplinary Fundamental Technologies 1. Necessity to fulfill mission of company activity 2. What is QFD(Quality Function Deployment)! 3. What is TRIZ! 4. What is Taguchi Method! 1) What is Taguchi Method? 2) Basics of Taguchi method 3) Summary of Taguchi method 4) Application to software 5) Taguchi method case (31-legged race) 6) Approach and management for people who don't know Taguchi method#361-1) What is Taguchi method? • TRIZ can be strongly promoted because there is Taguchi method Taguchi method is vital for strongly promoting TRIZ The world's best comfort technical method to secure quality in research / development / design stage 1. The founder Dr. Genichi Taguchi (1924-) 2. Action start from about 1950 3. 1960 Received Deming Prize He is called the man who revivified the U.S.A. 4. In the middle of 1980's, he applied Taguchi method to stagnant American auto industry and brought it back Demonstrated that Taguchi method is practical 6. 1988 Inducted into United States Hall of Fame of International Science & Technology (Da Vinci, Newton the sixth living person) 7. 1993 "The Taguchi Method Forum” established in Japan (Changed to Quality Engineering Society) 8. 1994 Inducted into United States Hall of Automation (Soichiro Honda, Eiji Toyoda, Genichi Taguchi, Yutaka Katayama, Jiro Yanase, Shoichiro Toyoda) 9. 1997 Dr. Taguchi entered American car palace (The third Japanese. Six present)#37output A general idea of control engineering 2) Basics of Taguchi method (1) We have to control characteristic of control factors to minimize influence of noise factors Input system 3 Noise factor output input Small variations Large output Output input#382) Basics of Taguchi method (2) Orthogonal experiment control factor A B C D 11 1 1 1 123456789 1) Combined experiment with orthogonal arrays 2) Creating the factor effect chart 3) Estimate of the 1 2 2 2 1 3 3 3 4 2 1 2 3 2 3 1 1 2 7 3 3 2 effect chart 1 3 3 2 1 222333 23123 optimum by the factor Factor effect chart SN ratio 3 1 B 2 3 1 2 3 C D 1 2 3 1 2 A Sensitivity 1 2 3 1 2 3 1 2 3 1 2 3 A B C D Estimate of the optimum by the factor effect chart (1) In any case, Minimize variation Enlarge S/N ratio... SN ratio = 10 log (m²/02) (2) Then, Match the mean Adjust with sensitivity ... Sensitivity = 10 log (m²) We match the mean with the targeted value with having kept variation small#392) Basics of Taguchi method (4) Confirmation experiment (Experiment at the level of predicted control factor) 1) Predicting the level of control factor from the factor effect chart (1) From SN ratio, set up level of control factors that lessens variations (2) From Sensitivity, set up level of control factors that matches the mean with the targeted value 2) We perform an experiment for confirmation whether the target characteristics are met under the limit condition of the variation (N1, N2) that took an error factor into account If basic design is a bad system, the limit of a system becomes clear (Teaches early that there is no use to carry on) In this case, the decision for a fresh design start enables lean development If basic design is a good system, Both are O a system of good quality with little variation is completed#403) Summary of Taguchi method (1) Current quality field problems barren money Development / Design Trouble in quality finish Factory Market Low yield ratio Hard-core large variations fresh start by lot rejection Hard-core overtime work and holiday work Defective returned goods from customers There are many reworks Taguchi method is a tool that meets quality field problems The best tool for a quality finish A tool that puts its first priority to thoroughly suppress variation A tool that prioritizes customer viewpoint and puts its first priority to thoroughly meet the change of environmental condition in markets#41(C) 3) Summary of Taguchi method (2) Taguchi method is Dr. Taguchi's heartfelt appeal! A theory that arose from "Companies must be strong in cost" A theory suitable to fulfill the mission of the company Company has to make good products early and cheaply A theory for creating little variation (good quality) products from much variation (cheap) parts A wise remark "Quality first" crushes the company of Dr. Taguchi#42D 3) Summary of Taguchi method (3) Conventional experiment Suddenly As a result of demanding quality goods Run into the Devil's Cycle • • We are going to make the most suitable thing We are going to make a thing of good quality Experiment of Taguchi method Two phases of designs . • Defective products are rather made Minimize variation (first phase) We find the optimum (second phase) We make quality goods with a confirmation experiment made thing is defective produc Conventional type: Development type to prevent from repeating failures Development type to solve the problem beforehand with Taguchi method No never-ending cycle Straight to the result Sure approach#434. Application to software Effect of Utilizing "orthogonal array, Introduction • excellent time efficiency and • increase in bug discovery rate were tried I hope that you utilize it hereafter for "bug elimination on the market”#444-1) Why are combination tests difficult? Are combination tests done? (1) Combination condition number is enormous For 100% combination for 3 factors Hundreds of thousands to several million module level cases Number of cases realistically testable is less than 1,000 (2) Difficult to separate accurately because of complicated conditions (3) Number of tests further goes up ✓ by state transitions through combined conditions In traditional testing, no remedy but evidently to take second best Inescapably, introduction of combination bugs#454-2) What is an Orthogonal array? Usually uses the 2 Level System ( 2, 4, 8, 16, 32, 64, 128, 256, ) [Column] Corresponds to function for software verification # of levels # of levels # of levels # of levels # of levels # of levels # of levels 4 4 4 2 2 2 column 1 column 2 column 3 column 4 column 5 column 6 column 7 [Row] Corresponds to row 1 1 1 1 1 1 1 1 verification number for row 2 1 2 2 2 1 2 2 software verification row 3 1 3 3 3 2 1 2 row 4 1 4 4 4 2 2 1 row 5 2 1 2 4 2 1 2 Combination of columns 1 and 2 row 6 2 2 1 3 2 2 1 row 7 2 3 4 2 1 1 1 Levels 1 to 4 for column 1 row 8 2 4 3 1 1 2 2 Levels 1 to 4 also for column 2 row 9 3 1 3 2 2 2 1 row 10 3 2 4 1 2 1 2 Each of the combinations of each level of columns 1 and 2 appears once: 1-1, 2-3, 3-4, etc. row 11 3 3 1 4 1 2 2 row 12 3 4 2 3 1 1 row 13 4 4 3 1 2 2 row 14 4 2 3 4 1 1 row 15 4 3 2 1 2 2 row 16 4 2 2 2 Combination of columns 4 and 5 Levels 1 to 4 for column 4 Levels 1 to 2 for column 5 Each of the combinations of each level of columns 4 and 5 appears twice: 1-1, 2-1, 3-2, etc. Combination of columns 6 and 7 Levels 1 to 2 for column 6 Levels 1 to 2 also for column 5 Each of the combinations of each level of Columns 6 and 7 appears four times: 1-1, 1-2, 2-1 and 2-2#464-3) Characteristics of Orthogonal array 1) All the levels described by 1 factor ( 1 function) can be checked ( 100% cover rate) ... 2) All the combinations of 2 factors ( 2 functions) can be checked ( The greatest characteristic 100% cover rate) 3) Combinations of 3 factors (3 functions) can be checked with about 60% to 80% cover rate, unintentionally 4) Combinations of 4 factors (4 functions) can be checked with about 30% to 50% cover rate, unintentionally 5) near to 100% cover rate possible as relation combinations (assuming inputs of every 5 years for years and every 3 days for days because the numbers of them are large )#474-4) Embedded software test method using orthogonal array MOSTEST method (Method using Orthogonal array for Software Evaluation Testing) Feature / Effect Some creative thinking in the orthogonal array Realizes 100% cover rate (2 factor combination test) using orthogonal arrays based on Taguchi method with excellent time efficiency and accuracy Secure discovery of Overview of MOST's software verification tool 1. Enter the relationships between condition factors and configuration factors 2. Enter simple factors and their levels state transition paths 1. Enter state transition relations 2. Clarifies needed tests (automatically) 3. Enter factors and their levels Automatically finds the optimal orthogonal array from the arranged 1909 kinds (variants of L256, L128, L64, L32, L16), and automatically generates an orthogonal array (describing factors and levels) for bug verification • 2 level system L16 max 16 factors, L8 max 25 factors, L4 max 32 factors, L2 levels max 254 • Simultaneous processing possible for 4 kinds of factor ( One of L16, L8, L4 or L2) • Level of configuration factors is one of L16, L8, L4 or L2 (level # of condition factor 1 * level # of condition factor 2 * level # of condition factor 3 * level # of condition factor 4* level # of configuration factor <= 256#485-1) Taguchi method practical case introduction Shoudai-Daini Municipal Elementary School, Yanagawa City, Fukuoka Prefecture (Unwittingly practicing Taguchi method truly) Question National winner in 31-legged race! "What kind of derby is the 31-legged race?” Answers of many "One to run keeping steps with each other???"#49What kind of approach did they take? 1. What is the basic function? "31-legged race" is a derby running Taguchi method vision to all day-to-day affairs! 'the same number of steps" "at the same speed" "keeping in line", 2. How was the goal set? All ran 50 meters one at a time Quality control method Number of steps: central value of all was 34 steps Speed: time level of national winner was 9.2 seconds 3. What kind of practice was taken? All purchased a stopwatch Nothing was created Practiced to count 34 in 9.2 seconds 4. How was the variation? Wonder: Wow, variation of 0.03 seconds! Time at national championship Less than Olympian in the 100m Game 1: 9.29s Game 2: 9.26s Semifinal: 9.28s Final: 9.28s#506) Approaches and management for people who don't know Taguchi method The approach and management for research / development / design that is firmly believed to be best and performed everyday by almost all the people who do not use Taguchi method: 1) design it 2) make a trial product 3) detect malfunction 4) study a cause of malfunction 5) remove the cause of malfunction Recurrence prevention type development 6) change the design to adjust to the standard 6) raise the completeness by repeating the process 1) - 6) many times 7) Whenever malfunction happens in the market, test method is added and a severer evaluation standard is set Let's immediately stop with such an inefficient approach and management that lacks logic! New technical field development proactive type development Taguchi method#51III-1) Summary Creative problem solving process and scientific methods To use TRIZ well, “QFD" and "Taguchi method" must be used well changing the time The relation among the 3 major methods is that none of them is superior to the others There are only time lags in their activities Defines system requirement function and problem availability QFD area Taguchi method area realizes the best system TRIZ area QFD " " secures system quality Research Development Design Production time axis#52III-2) Summary Difference between scientific method utilization Outcome (profit) 0 and common management! Scientific method applied management Bring result of QFD review! ( Review closely! Utilize scientific methods! ( Play full out!) Utilize scientific methods! ( Give it your all! Show ideas generated with TRIZ! ( Combine the wisdom of all! ) Bring data of Taguchi method review! (Reduce defects radically! ) What and how to do? Trial and error by the manager and also by the person in charge Consequently, difficulty yielding results Scientific methods are not magic tools! They are effective like magic, but it is to go over consistently, without omission, robustly, and at world-class level and to make to make to do so! Common management Review substantially! Give it your all! Play full out! Combine the wisdom of all! Reduce defects radically! Input energy (man, things, money)#53III-3) Summary What is TRIZ for managers! 1. Clarification of goals (The higher the goal, the better) QFD Product concept (goal) 2. Research and Development... What kind of thing can be technically done? Design... We want to largely lower component cost TRIZ Schema clarification on the desk (with the brain only) (Product creation that makes positive impression on customers) Enables structure determination of a perfect system that is good in QCD 3. * System configuration ideas to ensure the quality requested by the customers and • Embodiment on the desk (brain only) • Foresee the future (from tactics to strategies) Concrete product concept determine concrete condition setting ( set value) at product creation * pinpoint the true factor of large variations and determine the improve conditions * Determine the conditions so that quality can be ensured even with cheap materials * Determine operating condition of equipment in the factory Products creation Taguchi method tolerant of error conditions#54Thank you for your attention! I hope that you will further improve your management by acquiring or making to acquire good methods and performing good management ( utilization of scientific methods