Computer-aided engineering (CAE)

Computer-aided engineering (CAE) is the broad usage of computer software to aid in engineering tasks. It includes computer-aided design (CAD), computer-aided analysis (CAA), computer-integrated manufacturing (CIM), computer-aided manufacturing (CAM), material requirements planning (MRP)and computer-aided planning (CAP) Computer-aided engineering (CAE) means Use of computer systems to analyze CAD geometry Allows designer to simulate and study how the product will behave, allowing for optimization Finite-element method (FEM) Divides model into interconnected elements Solves continuous field problems

Components of CAD/CAM/CAE Systems

o o o Major component is hardware and software allowing shape manipulation Hardware includes graphic devices and their peripherals for input and output operations Software includes packages that manipulate or analyze shapes according to user interaction

In general, there are three phases in any computer-aided engineering task: Pre-processing defining the model and environmental factors to be applied to it. (typically a finite element model, but facet, voxel and thin sheet methods are also used) Analysis solver (usually performed on high powered computers) Post-processing of results (using visualization tools)

CAE areas covered include:

Stress analysis on components and assemblies using FEA (Finite Element Analysis); Thermal and fluid flow analysis Computational fluid dynamics (CFD); Multibody dynamics(MBD) & Kinematics; Analysis tools for process simulation for operations such as casting, molding, and die press forming. Optimization of the product or process. Safety analysis of postulate loss-of-coolant accident in nuclear reactor using realistic thermal-hydraulics code.

Applications of CAE Tools in Automotive Industry:

CAE tools are very widely used in the automotive industry. In fact, their use has enabled the automakers to reduce product development cost and time while improving the safety, comfort, and durability of the vehicles they produce. The predictive capability of CAE tools has progressed to the point where much of the design verification is now done using computer simulations rather than physical prototype testing. CAE dependability is based upon all proper assumptions as inputs and must identify critical inputs (BJ). Even though there have been many advances in CAE, and it is widely used in the engineering field, physical testing is still used as a final confirmation for subsystems due to the fact that CAE cannot predict all variables in complex assemblies (i.e. metal stretch, thinning). ***********************

Designing to Codes and Standards

Abstract:
The fundamental need for codes and standards in design is based on two concepts, interchangeability and compatibility. When manufactured articles were made by artisans working individually, each item was unique and the craftsman made the parts to fit each other. When a replacement part was required, it had to be made specially to fit. However, as the economy grew and large numbers of an item were required, the handcrafted method was grossly inefficient. Economies of scale dictated that parts should be as nearly identical as possible, and that a usable replacement part would be available in case it was needed. The key consideration was that the replacement part had to be interchangeable with the original one. Regardless of the material to be used, most design projects are exercises in creative problem solving. If the project is a very advanced one, pushing the boundaries of available technical knowledge, there are few guidelines available for the designer. In such instances, basic science, intuition, and discussions with peers are common approaches that combine to produce an approach to solving the problem. With the application of skill, daring, a little bit of luck, money, and patience, a workable solution usually emerges. However, most design projects just are not that challenging or different from what has been done in the past. Historically, such information was carefully guarded and was often kept secret. With the passage of time, however, these privately developed methods of solving design problems became common knowledge, ever more firmly established. Eventually they evolved into published standards of practice. Some government entities, acting under their general duty to preserve general welfare and to protect life and property from harm, added the standards to their legal bases. The need for codes and standards The fundamental need for codes and standards in design is based on two concepts, interchangeability and compatibility. When manufactured articles were made by artisans working individually, each item was unique and the craftsman made the parts to fit each other. When a replacement part was required, it had to be made specially to fit. However, as the economy grew and large numbers of an item were required, the handcrafted method was grossly inefficient. Economies of scale dictated that parts should be as nearly identical as possible, and that a usable replacement part would be available in case it was needed. The key consideration was that the replacement part had to be interchangeable with the original one. Standardization of parts within a particular manufacturing company to ensure interchangeability is only one part of the industrial production problem. The other part is compatibility. What happens when parts from one company, working to their standards, have to be combined with parts from another company, working to their standards? Will parts from company A fit with parts from company B? Yes, but only if the parts are compatible. In other words, the standards of the two companies must be the same. Purposes and objectives of codes and standards The protection of general welfare is one of the common reasons for the establishment of a government agency. The purpose of codes is to assist that government agency in meeting its obligation to protect the general welfare of the population it serves. The objectives of codes are to prevent damage to

property and injury to or loss of life by persons. These objectives are accomplished by applying accumulated knowledge to the avoidance, reduction, or elimination of definable hazards. Before going any further, the reader needs to understand the differences between "codes" and "standards". Which items are codes and which are standards? One of the several dictionary definitions for "code" is "any set of standards set forth and enforced by a local government for the protection of public safety, health, etc., as in the structural safety of buildings (building code), health requirements for plumbing, ventilation, etc. (sanitary or health code), and the specifications for fire escapes or exits (fire code)". "Standard" is defined as "something considered by an authority or by general consent as a basis of comparison; an approved model". As a practical matter, codes tell the user what to do and when and under what circumstances to do it. Codes are often legal requirements that are adopted by local jurisdictions that then enforce their provisions. Standards tell the user how to do it and are usually regarded only as recommendations that do not have the force of law. As noted in the definition for code, standards are frequently collected as reference information when codes are being prepared. It is common for sections of a local code to refer to nationally recognized standards. In many instances, entire sections of the standards are adopted into the code by reference, and then become legally enforceable. How standards develop Whenever a new field of economic activity emerges, inventors and entrepreneurs scramble to get into the market, using a wide variety of approaches. After a while the chaos decreases, and a consensus begins to form as to what constitutes "good practice" for that economic activity. As an industry matures, more and more companies get involved as suppliers, subcontractors, assemblers, and so forth. Establishing national trade practices is the next step in the standards development process. This is usually done through special institutions like the American National Standards Institute (ANSI), which provides the necessary forum. A sponsoring trade association will request that ANSI review its standard. A review group is then formed that includes members of many groups other than the industry, itself. This expands the area of consensus and is an essential feature of the ANSI process. ANSI circulates copies of the proposed standard to all interested parties, seeking comments. A time frame is set up for receipt of comments, after which a Board of Standards Review considers the comments and makes what it considers necessary changes. After more reviews, the standard is finally issued and published by ANSI, listed in their catalog, and available to anyone who wishes to purchase a copy. A similar process is used by the International Standards Organization (ISO), which began to prepare an extensive set of worldwide standards in 1996. One of the key features of the ANSI system is the unrestricted availability of its standards. Company, trade, or other proprietary standards may not be available to anyone outside that company or trade, but ANSI standards are available to everyone. With the wide consensus format and easy accessibility, there is no reason for designers to avoid the step of searching for and collecting any and all standards applicable to their particular projects. Types of codes There are two broad types of codes: performance codes and specification or prescriptive codes. Performance codes state their regulations in the form of what the specific requirement is supposed to achieve, not what method is to be used to achieve it. The emphasis is on the result, not on how the

result is obtained. Specification or prescriptive codes state their requirements in terms of specific details and leave no discretion to the designer. There are many of each type in use. Trade codes relate to several public welfare concerns. For example, the plumbing, ventilation, and sanitation codes relate to health. The electrical codes relate to property damage and personal injury. Building codes treat structural requirements that ensure adequate resistance to applied loads. Mechanical codes are involved with both proper component strength and avoidance of personal injury hazards. All of these codes, and several others, provide detailed guidance to designers of buildings and equipment that will be constructed, installed, operated, or maintained by persons skilled in those particular trades. Safety codes, on the other hand, treat only the safety aspects of a particular entity. The safety codes sets forth detailed requirements for safety as it relates to buildings. Professional society codes have been developed, and several have wide acceptance. The American Society of Mechanical Engineers (ASME) publishes the Boiler and Pressure Vessel Code, which have been used as a design standard for many decades. The Institute of Electrical and Electronic Engineers (IEEE) publishes a series of books that codify recommended good practices in various areas of their discipline. The Society of Automotive Engineers (SAE) publishes hundreds of standards relating to the design and safety requirements for vehicles and their appurtenances. The American Society for Testing and Materials (ASTM) publishes thousands of standards relating to materials and the methods of testing to ensure compliance with the requirements of the standards. Statutory codes are those prepared and adopted by some governmental agency, local, stale, or federal. They have the force of law and contain enforcement provisions, complete with license requirements and penalties for violations. There are literally thousands of these, each applicable within its geographical area of jurisdiction. Regulations. Laws passed by legislatures are written in general and often vague language. To implement the collective wisdom of the lawmakers, the agency staff then comes in to write the regulations that spell out the details. Types of standards Proprietary (in-house) standards are prepared by individual companies for their own use. They usually establish tolerances for various physical factors such as dimensions, fits, forms, and finishes for inhouse production. When outsourcing is used, the purchasing department will usually use the in-house standards in the terms and conditions of the order. Quality assurance provisions are often in-house standards, but currently many are being based on the requirements of ISO 9000. Operating procedures for material review boards are commonly based on inhouse standards. It is assumed that designers, as a function of their jobs, are intimately familiar with their own employers standards. Government specification standards for federal, state, and local entities involve literally thousands of documents. Because government purchases involve such a huge portion of the national economy, it is important that designers become familiar with standards applicable to this enormous market segment. To make certain that the purchasing agency gets precisely the product it wants, the specifications are drawn up in elaborate detail. Failure to comply with the specifications is cause for rejection of the sellers offer, and there are often stringent inspection, certification, and documentation requirements included. It is important for designers to note that government specifications, particularly Federal specifications, contain a section that sets forth other documents that are incorporated by reference into the body of the primary document. These other documents are usually federal specifications, federal and military

standards, and applicable industrial or commercial standards. The MIL standards and Handbooks for a particular product line should be a basic pan of the library of any designers working in the government supply area. Product definition standards are published by the National Institute of Standards and Technology under procedures of the Department of Commerce. It establishes the grading rules, names of specific varieties of soft wood, and sets the uniform lumber sizes for this very commonly used material. Commercial standards (denoted by the letters CS) are published by the Commerce Department for articles considered to be commodities. Commingling of such items is commonplace, and products of several suppliers may be mixed together by vendors. The result can be substantial variations in quality. To provide a uniform basis for fair competition, the Commercial Standards set forth test methods, ratings, certifications, and labeling requirements. Testing and certification standards are developed for use by designers, quality assurance agencies, industries, and testing laboratories. International standards have been proliferating rapidly for the past two decades. This has been in response to the demands of an increasingly global economy for uniformity, compatibility, and interchangeability demands for which standards are ideally suited. Beginning in 1987, the International Standards Organization (ISO) attacked one of the most serious international standardization problems, that of quality assurance and control. These efforts resulted in the publication of the ISO 9000 Standard for Quality Management. This has been followed by ISO 14000 for Environmental Management Standards, which is directed at international environmental problems. The ISO has several Technical Committees (TC) that publish handbooks and standards in their particular fields. Examples are the ISO Standards Handbooks on Mechanical Vibration and Shock, Statistical Methods for Quality Control, and Acoustics. All of these provide valuable information for designers of products intended for the international market. Codes and standards preparation organizations U.S. Government Documents. For Federal government procurement items, other than for the Department of Defense, the Office of Federal Supply Services of the General Services Administration issues the Index of Federal Specifications, Standards and Commercial Item Descriptions every April. The American National Standards Institute also publishes a catalog of all their publications and distributes catalogs of standards published by 38 other ISO member organizations. They also distribute ASTM and ISO standards and English language editions of Japanese Standards, Handbooks, and Materials Data Books. ANSI does not handle publications of the British Standards Institute or the standards organizations in Germany and France. As mentioned previously, there are many organizations that act as sponsors for the standards that ANSI prepares under their consensus format. The sponsors are good sources for information on forthcoming changes in standards and should be consulted by designers wishing to avoid last-minute surprises. Listings in the ANSI catalog will have the acronym for the sponsor given after the ANSI symbol. The field of interest of each sponsor is usually obvious from the name of the organization. Designers responsibility As soon as a designer has been able to establish a solid definition of the problem at hand, and to formulate a promising solution to it, the next logical step is to begin the collection of available reference materials such as codes and standards. This is a key part of the background phase of the design effort. Awareness of the existence and applicability of codes and standards is a major responsibility of the designer. One of the designers responsibilities in the background phase is to make certain that the collection of

reference codes and standards is both complete and comprehensive. Considering the enormous amount of information available, and the ease of access to it, this can be a formidable task. However, a designers failure to acquire a complete and comprehensive collection of applicable standards is ill advised in todays litigious environment. In addition, failure of the designer to meet the requirements set forth in the standards can be considered professional malpractice.

Quality Function Deployment Quality deployment is defined as a methodology that converts user demands into substitute quality characteristics, determines the design quality of the finished goods and systematically deploys this quality into component quality, individual past quality and process elements and their relationships. QFD Methodology It was first developed by Akao, and its first application was in Japan. He developed the approaches called Matrix of Matrices. Since then a second method has been developed and primarily used in American applications. It is generally referred to as the four-phased approach and was developed originally by the American Supplier Institute. These two approaches utilize a similar matrix, but go about application of the analyses in different ways. The two methods are also heavily focused on products and processes.

Four-phased Approach The four-phased approach to QFD is accomplished by using a series of matrices that guide the product teams activities by providing standard documentation during product and process development. Although the four elements of the approach vary depending upon the application. The basic four phases of the approach that structure QFD Matrixes are four major activities. Programme Planning Product Design Process Planning Process Control Planning The ability to trace design features and process needs back to customer requirements Is formed by taking the design characteristics from the top of the initial matrix and using them as the left-hand side of

the next matrix.This process continues until specific product and process specifications and manufacturing guidelines result. The Core of QFD Matrix The core of QFD matrix is based on a matrix that is some times referred as the House of Quality. The house of quality is used to initiate a comparison of customers needs with the technical requirements of the products.

Identify Customer Needs The core QFD matrix begins by using the customers physical and functional needs (attributes). Customers can be primary or secondary customers. Customers can be either internal or external to the organization and their needs may be conflicting. Some times it is necessary to focus who is the actual end user of the product or services in order to determine who the final customer is. There are several categories of customer needs. The first category consists of explicit customer expectations.The second category involves elements a customer expects without telling you. The last group of customer needs is excitement factors. Prioritize Needs and Conduct Competitive Benchmarking The matrix is used to prioritize customer needs and develop competitive benchmarks. The first step in prioritization is to assume that not all customer needs can be equally important. The core QFD matrix measures the relative importance to the customer of all of the defined needs. Weighed values based on customers perception are designed from the team members direct experience with the customers or from the surveys. Develop Technical Requirements The next step involves brain storming a list of technical characteristics or requirements that will satisfy the customer needs. The term Technical requirements is used to group product, service and operational requirements that will satisfy customers needs at the top level of analysis. Co-relate Technical Requirements to Customer Needs The relationship matrix indicates the impact of each technical requirement on the customers needs. A project team should seek consensus on evaluations basing them on expert engineering or service knowledge and experience, customer responses and tabulated data from statistical studies. Priorities Technical Requirements The relationship matrix can be transported into design priorities. The relational level of importance, what is important and define what is least important. Set Specific Targets At the bottom of the core QFD matrix, targets are set for each corresponding characteristics to measure the process, service, or product design. If the characteristic is not measurable, then further definition is required. If a characteristic can not be measured then there is no way to verify that it has been implemented into design, or integrated into manufacturing process or included in the service. Identify Technical Interactions In a QFD matrix these connections between the system characteristics are captured at the top of the matrix in what is traditionally referred to as the root. The distinctive roof of the core QFD matrix assists engineers or members of the multi-functional team in specifying various characteristic features that need to be improved collaterally. System characteristics exhibiting negative relationships are trade off to find the best compromise and strong positive relationships are studied to prevent duplication of the effort. Concept Evaluation Product or service concepts can be evaluated against all technical requirements as related to customer needs. Each independent element of a particular concept can be evaluated for strength and weakness

compared to the performance targets set during QFD analysis. This analysis also permits the design team or the development team to determine if there are any gaps in the concepts technical solutions that would prevent meeting performance goals. As a result, the concept in that can c then be compared to another concept to determine overall ability to meet the customers priority needs as determined earlier in the analysis.

Case Study-About the SB CNC / 40/60 Slat Bed Turning Centre manufactured in HMT Kalamassery 1. Introduction
The purpose of the project is to improve the existing SBCNC 40/60 Slant Bed Turning Center, manufactured in HMT, Kalamassery. About the SB CNC / 40/60 Slat Bed Turning Centre manufactured in HMT Kalamassery HMT Kalamassery plant is manufacturing SB CNC 40/60 Slant Bed machine Centre for the last 25 years. The company is equipped with best and automated foundry, world class manufacturing facilities and design team. The SBCNC 40/60 Slant Bed Turning centre is basically used in Defence Sector, and in heavy equipment manufacturing companies like BHEL, BMEL, KSB, Instrumentation etc. CNC Slant Bed Turning centre SB CNC 40/60 is designed on advanced concepts for the economic machining of standard and exotic materials with cutting tools ranging from coated carbide and ceramics to CBN and PCD tooling system.

2. Quality Function Deployment

Quality deployment is defined as a methodology that converts user demands into substitute quality characteristics, determines the design quality of the finished goods and systematically deploys this quality into component quality, individual past quality and process elements and their relationships.

3. Problem Description
HMT Kalamassery unit is manufacturing SB CNC Slant bed Turning Centre in the last 25 years. In the last several years the sales of the machine is dropped. Presently it is selling only 10 to 15 machines annually. The Machine is used in the Heavy Machinery manufacturing units like Earth Moving machine manufacturing units, construction machinery manufacturing units, military vehicle manufacturing machines etc. Very few companies are manufacturing such machines in India. The main competitors are (1) MIVEN Hubli, (2) PROTECH Chennai. The purpose of this study is to: Identify the functional problems of the machine and rectify. Improve the capacity of the machine if needed. Improve the aesthetics of the machine Make the machine more user friendly and Ultimately improve the customer satisfaction and improved sales. Develop Prioritized Customer Requirements of the Internal and External Customer is taken Develop Prioritized Technical Descriptors were Calculated Self-Completion Questionnaire They are low cost since there is no interviewer involved. They are least instructive form of data collection and respondents co-operate with self compilation questionnaire. Distance is immaterial and there is wide choice of methods for distributing questionnaire. In addition to post, fax machine can be used. Personal delivery and collection improves response rate and saleable. Envelopes can be provided

to suggest confidentiality. Self compilation questionnaires are particularly useful method of capsuling customers vens at the point of consumption. Despite these many attractions, self compilation questionnaires do have serious disadvantages. The questionnaires have to be reasonably short and questions simple. Any perceived difficulty in completing the exercise will have a considerable adverse effect on response rate. They are very slow and leave them in pending trays. The most serious drawback of self compilation questionnaire is the accuracy of the data generated. There are two problems here. Firstly respondents tend to reply very hurriedly and with little thought. As a result, questionnaire misinterpreted or omitted. Secondly very low response rate. Before Designing Questionnaire The characteristic functional problems, need of automation, user friendliness, aesthetics and additional features prepared for the HMT SB CNC 40/60 Turning Centre are identified after consultation with the HMT Design Dept, Service Dept, Sales Dept and Quality Control Dept. The additional features or capacity of the immediate competitors are also studied. The Following are the Expected Modifications User friendly Aesthetics o Handles o Protective Covers o Switches change o Colour change Functional Problems Failure of indigenous items o Manufactured o Contract Manufactured Oil leakage (Hydraulic) Coolant leakage (Fabrication problem) Turret change (Hydraulic to Electric) Capacity o Stock Removal Rate o Accuracy

How to answer the Questionnaire? Kindly read the question before deciding the most accurate grading from a scale of 9. For eg. If you feel the level of grading is 9 then circle box no. 9 as in figure.
1 2 Of no Importance at all 3 Quite Unimportant 4 5 Quite 6 7 8 (9) Extremely Important

Important

Customers Feedback Questionnaire HMT SBCC 40/60 Slant Bed Turning Centre 1. The lathe has to be user friendly. 2. Handles / switches have to be good Looking and should provide a good Appearance to the lathe. 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

3. Manual doors are difficult to operate and should be replaced with Automated doors. 4. Colours of the machine are dull and must be replaced with bright, Attractive and durable paint finish. 5. Certain machine components fail Frequently. Components should have a high MTBF (Mean time between failures) should be graded with high quality. 6. Hydraulic oil leakage occurs frequently. It has to be rectified. 7. Lubrication oil leakage occurs frequently. It has to be rectified. 8. Coolant leakage occurs frequently. It has to be rectified. 9. Brighter lights have to be provided In the machine area. 10. Work loading device has to be automated, so that heavy jobs can be loaded easily. 11. Online inspection facilities have to be Provided. 12. Power usage can be reduced by replacing gear box with a direct drive motor. 13. Provision for online maintenance must be provided 14. To improve the safety of machine, European Safety Standards must be Provided. 15. The machine system should have the capacity to automatically communicate with each sub machine. 16. FMS/CIM is available on the machine 17. Should tool automation (Auto tool changer / tool magazines) be provided. 18. Higher geometrical accuracy (IT 7, IT 6, IT 5) is available on the machine. 19. Hydraulic turret subjected to oil leakage,

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

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1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

it has to be rectified. 20. Metal removal rate has to be improved. 1 2 3 4 5 6 7 8 9

Customer Requirements User friendly (Easy to operate the lathe)

Technical Description (a) Software (Error identifying system) (b) Monitor (moving from left to right) (c ) Interlocking (operator make mistake, machine stops) (d) System user friendly (e) Menu driven (f) USB, Ethernet, communication (PC based) (a) Ergonomically designed imported (a) Door interlock (door switch imported) (b) Pressure switch (imported) (a) Small electric motor with reduction gear (b) Improve design for easy movement (a) Polyuthene paint (b) Paint booth (c ) Powder coating (a) Higher grade/Quality components (b) Manufacturing set-up has to be improved (presently machines are old) (c) Improve quality of components - Casting made outside HMT does not have good quality - Contract workers produces inferior quality components (a) Oil chillers has to be provided (to reduce the hydraulic oil temperature) (b) Better connectors, O-rings, Tubes (c ) Better workmanship (d) Base casting modified with separate oil passage (a) Closed system (System has to be redesigned to collect the excess oil and recycle). (b) Poor workmanship (c ) Better connectors, O-Ring, Hose (a) Sheet metal modification (must be made by CNC press shop)

Handles Switches Manual Doors Colours

3 4

Higher MTBE

Hydraulic oil leakage

Lubrication leakage

Coolant leakage

(b) Mounting area between base casting and sheet metal must be proper (Base casting should have grooves so leaking will not take place, base mould has to be changed) 9 Brighter light (c ) Poor workmanship (a) LED lights + movable spot light (b) Halogen lights + movable spot light (a) Jib crane (Pneumatic Servolift) (b) Gandary type / Load Balancer (a) Job probe inspection station (b) Post process for the machine tool (c ) Automatic Post process (a) Using direct driven motor without gear box (a) TPM software total productivity maintenance software (b) Self diagnostic system Error kits (a) Obtain European Safety Standards (a) Communication with similar machines (a) Facilities to connect all machines with the main server. Communicate with each sub system and take commands from the main server (a) If the tools required is >12 tool magazine has to be provided a) Hydraulic guide ways b) Hydrostatic spindles c) Ball screw change d) Machine must be maintained in controlled temperature e) Bed should be vibration free f) Linear scale g) Bearing change h) Axis accuracy a) Servo turret b) Improved quality of material and workmanship c) Proper final assembly d) Total design change of the Turret a) Stiffness / Rigidity improve b) Change, saddle, Turret Bearing, casting etc.

10 Work loading 11 Online inspection

12 Motor with Gear Box 13 On-line maintenance

14 European Safety Standards 15 Machine system communicate with subsystem 16 FMS/CIM availability

17 Tool automation 18 Higher geometrical accuracy (IT5)

19 Hydraulic turret

20 Metal Removal Rate (Speed, feed, depth of cut)

The inter-relationship (weight-age) between technical descriptors and customer requirements were decided after consultation with Quality Control Dept., HMT, Kalamassery. The weight-age between the technical descriptors was chosen after consultation with the Quality Control Dept. HMT, Kalamassery. Building a House of Quality List of Customer Requirements (WHATs) This list is often referred as the what that customer needs or expects in a particular product. The requirements must be clearly represent with minute details. Internal Customers Prioritized customer requirements Lathe has to be user friendly. Hydraulic oil leakage occurs frequently. Hydraulic turret subject to oil leakages. Coolant leakage occurs frequently. Brighter light has to be provided. Tool automation has to be provided. Handles/switches have to be good looking. Automated doors are needed. FMS/CIM is available on the machine. Provision for online maintenance is required. Online inspection facilities have to be provided. Colours must be bright, attractive and durable. The machine components should have high MTBF (Mean time between failures). Lubrication oil leakage occurs frequently, it has to be rectified. Geared spindle meter must be replaced with direct driven motor. Machines can be networked (communicate with each other). For the safety of the machine, European Safety standards may be followed. Metal removal rate has to be improved. Replacing grinder motor spindle drive with a direct drive motor. Loading device has to be automated. External Customers Prioritized customer requirements Brighter light in the machine area. Machine compounds have higher MTBF (Mean time between failures) and graded with high quality. Hydraulic oil leakage has to be rectified. Lathe has to be user friendly. Lubrication oil / leakage have to be rectified. Coolant leakage has to be rectified. Handles / switches have to be good looking. Hydraulic turret oil leakage has to be rectified. Provision for online maintenance must be provided. Replacing gears and motor for a direct drive meter. Machine should have the capacity to communicate with other machines. Improve metal removal rate.

 European safety standards must be followed. Higher geometrical accuracy is required (175 or 174). Bright, attractive and durable paint is required. FMS/CIM facilities must be available on the machine. Online inspection facilities have to be provided. Provision for automation is provided on the machine. Automated (motorized) doors have to be provided work loading has to be automated. Automated working loading device has to be provided. List of Technical Descriptions (HOWs) The goal of House of Quality is to design or change the design of a product in a way that meet or exceeds the customer satisfaction. Implementation of the customer requirements are treated into technical language. This provision similar to refining marketing specification into system-level engineering specification. Develop Relationship Matrix between WHATs and HOWs The next step in building a house of quality is to compare the customer requirements and technical descriptors and determine their respective relationships. The relationship matrix is used to represent graphically the degree of influence between technical descriptors and each customer requirements. 9 represent strong relationship 3 represent medium relationship 1 represent weak relationship Develop an Inter-relationship between HOWs The roof of the house of quality, the correlation matrix, is to identify any relationship between each of the technical descriptors. 9 represent strong relationship 3 represent medium relationship 1 represent weak relationship Manufacturing setup has to be improved. Sheet metal design modification (manufactured in CNC Automatic press Shop). Material (in-house casting) and better workmanship. Obtain European Safety Standard Certificate. Better workmanship. Software (a) Error Identifying System, (b) Self Diagnosis System. To cool the hydraulic oil, oil chillers can be used. Improve the design for easy movement of the door. Job-probe inspection station. Total productivity maintenance software has to be used. Using better connectors, tubes and O-ring. Ergonomically designed handles, switches (imported). Increase the stiffness / rigidity of the machine. Servo Turret. LED lights + moveable spotlight. Axis accuracy has to be increased. Facilities to connect all machines with master server. Re-design to collect the excess lubrication oil and recycle. If the required tool is better than 12, use tool magazine. Networking the systems (machine tools).

 Load balancer. Jib Crane. Poly Urethane paint. Post process for machine tool. Hydrostatics spindle. Menu driven. Gearless motor. Increase the speed. Prioritized Technical Descriptors (External Customers) Manufacturing setup has to be improved. Software (a) Error Identifying System, (b) Self Diagnosis System. Obtain European Safety Standard Certificate. Sheet metal design modification (manufactured in CNC Automatic press Shop). Material (in-house casting) and better workmanship. Better workmanship. To cool the hydraulic oil, oil chillers can be used. Total productivity maintenance software has to be used. Better connectors, Tubes and O-ring. Improve the design for easy movement of the door. LED lights + moveable spotlight. Job-probe inspection station. Axis accuracy has to be increased. Increase the stiffness / rigidity of the machine. Higher speed for spindle motor. Ergonomically designed handles, switches (imported). Servo Turret. Re-design to collect the excess lubrication oil and recycle. Gearless motor. Facilities to connect all machines with master server. Hydrostatics spindle. Jib Crane. Load balancer. Menu driven. Post process for machine tool. If the required tool is better than 12, use tool magazine. Poly Urethane paint. Communication with similar machines. Summary of Work Done Design of customers feedback questionnaire. After collecting the feedbacks of Internal and External customers, the feedbacks are prioritized. Technical descriptors were identified; analysed and best alternative for the problem is selected. QFD matrix is constructed. The output is (a) Prioritized technical descriptors of the External Customer, (b) Prioritized technical descriptors of the Internal Customers. 4. Conclusion

The prioritized technical characteristics of both Internal and External Customer are more or less same. 5. Scope for Future Work Fuzzy QFD can be formed. QFD can be modified using AHP. Interrelationship between customer and technical language can be studied using interpretive structural model. 6. Reference 1. Dale H. Besterfield, Carol besterfield. Total Quality Management, Prentice Hall, India. 2. Fiorenzo Franleschini, Advanced Quality Function Deployment, St. Lucie Press. 3. Barbara A. Bicknell, The Road Map to Repeatable Success. 4. Bossert, James, Quality Function Deployment, Milwaukee. 5. Bossert, James L., Quality Function Deployment: A Practitioners Approach, Milwaukee, WI: ASQ Quality Press, 1991. 6. Crosby, Philip B., Quality without Tears, New York: McGraw-Hill Book Company, 1984. 7. Deming, W. Edwards, Quality, Productivity, and Competitive Position, Cambridge, MA: Massachusetts Institute of Technology, 1982. 7. House of Quality