INGENIEUR
Figure 1: Validation Phase
NG
NG
S tep 6 - Validation
NG
Creation
OK
Internal Matching
-Identify possible
failure when apply
to machine and
process
- Apply FMEA
-Take preventive
action
-Verify product
function and quality
requirement
Internal
Matching
OK
Safety
Assessment
Safety Assessment
Customer Approval
-Fulfillment of safety
-Confirmation of product
requirement as stipulated performance as applied
by the safety hazard
at the customer line.
regulatory body
-Gather VOC for
-Obtain Certificate of
improvement
Fitness for User.
-Obtain customer consent
-Feedback safety test
result for continuous
improvement
Comparative analysis studies are not carried out
merely to imitate rivals but to identify and develop
breakthrough design targets that are superior
than the competitors.
Step 5 – Creation
This is the step where in which design targets
generated from comparative analysis studies
are put into practical design attributes of the
component. Every idea is thoroughly discussed,
debated and scrutinized before the final design is
decided upon for implementation. The decision is
mainly influenced by the following factors:
i. Four guiding questions related to the
reduction of weight, minimization of
geometry or shape, replacement with
alternative cheaper material and a more
effective manufacturing method to make
the component with minimal residual scrap;
ii. The ability of suppliers to manufacture the
proposed new component design
iii. Acceptance of customers to use the new
components in the product;
6
58
OK
Customer
Approval
VOL 62 APRIL – JUNE 2015
VOL 55 JUNE 2013
OK
Standard
Standard
-Drafting, revising and
issuing of standard
operating documents.
-Finalizing specifications
for new design
component, process and
machine settings.
iv. Suitability of the proposed new design
using existing machines, processes and
method of productions; and
v. Whether minimal adjustments can be
made to existing processes or machine
settings to avoid tedious changeover tasks
and complications which may lead to big
variation in product quality. A brainstorming
technique is normally applied to generate
ideas.
Step 6 – Validation
This is the design refine phase to validate the
design attributes. The results of the validation
conclude the integration of design attributes
into the product making at the manufacturing
processes. As such strict procedures have to be
observed such as:
i. Identifying or predicting ways in which the
new design may fail and prioritize action
plans to reduce the risk by using Failure
Mode and Effect Analysis or FMEA. Here,
FMEA is not only applied to anticipate the