Design For Craftsmanship MPD575 DFX Jonathan Weaver.

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Design For Craftsmanship MPD575 DFX Jonathan Weaver

Transcript of Design For Craftsmanship MPD575 DFX Jonathan Weaver.

Page 1: Design For Craftsmanship MPD575 DFX Jonathan Weaver.

Design For Craftsmanship

MPD575 DFX

Jonathan Weaver

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Development History• Originally developed by Cohort 1 students:

Dave Chronowski, Mark Halseth, Andrew Kernahan, & Roger Maynard (Fall 2000)

• Revised by Cohort 1 students: Robin Schulz, Beth Robinson (Fall 2000)

• Underhood examples provided by Lester Weitman added prior to presentation to Cohort 2 (Fall 2001)

• Revised by Cohort 2 students: Phil Fabien, Ilze Liepa, Joel Simmermon (Fall 2001)

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Development History (Cont.)• Examples from Cohort 2 assignments added

Fall 2001• Examples provided by Robert Ognjanovski

added Fall 2002• Later revised by Michael Vinarcik and Joe

Torres, Raghavan Setlur, Mac Lunn

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Development History

• Latest updates by many of the following students in winter of 2014: M. Freeman, H. Gasahl, R. Glaser, A. Kammerzell, J. Lambrecht, D. Mincock, J. Murphy, M. Rockwell, P. Roncier, J. Salinas, G. Scalcucci, D. Slater

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Objectives

• Define Craftsmanship In Engineering Terms And Heuristics

• Develop Key Methods And Structure For Evaluating Craftsmanship Of Consumer Products

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Contents• What Is Craftsmanship? • Influences On Craftsmanship • Motivation• Design For Craftsmanship Heuristics• Underhood Craftsmanship • Assessment Process

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Contents• What is Craftsmanship? • Influences on Craftsmanship • Motivation• Design for Craftsmanship Heuristics • Underhood Craftsmanship• Assessment Process

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What is Craftsmanship?

• How well executed a given design is in the eyes of the customer.

• Synonymous with extreme attention to detail, done right the first time, pride in workmanship, and requiring a certain level of expertise and dedication to achieve.

• In manufacturing, craftsmanship directly results from close communication between design, production, and skilled labor delivering quality product with pride.

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What is Craftsmanship?

• The 'extra' effort expended that allows a final product to surpass the normal limits of utility and functionality, entering the dimension of art and beauty.

• The ability of skilled workers to put their final touch on the product based on their years of experience and creative artistic skills. Therefore, Design for Craftsmanship, DFC, is the ability of the product designer to allow for such creativity!

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What is Craftsmanship?

• …harmony of the overall interior theme• The art and execution of quality. It captures the

customer’s perception of quality design and workmanship through sight, sound, smell, and tactile senses

• The blending of engineering, system architecting, and art to create a product that also has aesthetic appeal

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Craftsmanship Is...• a perception of

– quality– materials– weight/heft/solidity/sturdiness– texture– alignment– tactility– appearance– compatibility with environment

• a perception that value is enhanced

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Craftsmanship Is...• What is a Perception?

– the electronic touchscreen could be an example of growth area, for transitions, speed, intrusion/asking approval, smooth response and touch response

– a result of perceiving: observation – a mental image: concept– awareness of the elements of environment through physical

sensation <color perception> – physical sensation interpreted in the light of experience

• Evaluated by the senses - Sight - Sound - Feel/touch - Smell - Taste - Emotion

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Craftsmanship Is...

• Intangible (It Is Very Hard To Develop An Objective Metric)

• Attention To Detail• Highly Associated With Brand• Interpreted By The Customer• The Result Of Specific Efforts

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Craftsmanship Impacts…

• Things Gone Wrong• Things Gone Right• J. D. Power (or others’)

Ratings/Surveys• Customer Satisfaction• Customer Loyalty• Customer Perception of Quality

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Craftsmanship Is Not...

• Measurable Quality– R/1000, CPU

• Robustness• Functionality• Easily Quantifiable or Measurable

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Craftsmanship Is Often Free• It Costs Just As Much To Make It Ugly And

Slapdash!• Craftsmanship Requires More Up-front

Thought But Can Be Cheaper In The Long Run (Well-routed Hoses Easier To Service, Etc.)

• Craftsmanship Is The Clearest Way To Show A Customer That The Entire Organization (From Design To Engineering And Manufacturing) Cares About Details.

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Craftsmanship Qualification Scale

Objective

less quantifiable more

Measured via behavioral science

Measured via behavioral science

Subjective

Physicalmeasureable

Manufacturingquality

Measured via behavioral science

Physicalmeasureable

Measured via behavioral science

Measured via behavioral science

Physicalmeasureable

Measured via behavioral science

Manufacturingquality

Measured via behavioral science

Physicalmeasureable

Measured via behavioral science

Manufacturingquality

Measured via behavioral science

Physicalmeasureable

Measured via behavioral science

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Examples

• Each Class Member Should Share An Example Of Good Or Bad Craftsmanship

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How Do You Make Craftsmanship Happen?

• Engineers And Automotive Designers Work Together To Interpret The Customers’ Needs, Desires, And Expectations And Then Make Them Happen In The Physical World

• Two Sides To The Equation:– Engineering Design– Artistic Design

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Contents✓What is Craftsmanship? ✓Influences on Craftsmanship ✓Motivation✓Design for Craftsmanship Heuristics ✓Underhood Craftsmanship✓Assessment Process

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Influences on Craftsmanship

• Engineering Design – The Engineering Side Of Craftsmanship, The Part That Can Be Controlled– Cost– Design For Assembly– Design For Manufacture– Robustness Tools– Assembly Influences

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Cost

• Craftsmanship May Have A Cost Associated With It

• Difference Between A Focus And A Town Car Or A Cavalier And Cadillac– Any Vehicle Pair With The Same

Functionality, But Different Levels Of Craftsmanship

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Design For Assembly

• Craftsmanship Overlaps DFA In The Sense That If An Item Has Efficient DFA Then It Should Be Manufactured Such That It Meets The Design Intent.

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Design For Manufacture

• In The Same Sense As DFA, Craftsmanship Overlaps DFM - If An Item Has An Efficient DFM Then It Should Be Manufactured Such That It Meets The Design Intent.

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Robustness Tools

• Design Of Experiments– Reduce Variation– Find The Key Contributors– Control What Can Be Controlled

• Process Controls– Establish What Can Be Controlled– Monitor Those Items– Take Action When Out Of Control

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Robustness Tools

• Eliminating Excessive Variation In Key Processes Improves Craftsmanship

• Process Outputs That Impact Fit/Finish/Function Will Drive Customer Perceptions– Gaps Between Parts– Operating Efforts (Doors, Toolbox Lids,

Etc.)

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Assembly Influences

• Operator Dependence– This Is The Manufacturing Side Of Craftsmanship– Taking The FMEA Approach And Assuming The

Process And Design Have Been Optimized To Reduce Operator Dependence, Operators Must Be Trained And Motivated To Assemble The Product As The Designer Intended

– Ergonomics, Work Practices (Job Rotation, Skill Enhancement, Work Teams) All Play A Major Role

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Assembly Influences

• Jigs And Fixturing– This is a subset of DFA And DFM and helps

reduce or eliminate operator error

• Poke-yoke (Pronounced Poh-kah Yoh-kay) – Japanese practice that means elimination of error

through mandating design of product and/or tooling such that error is impossible.

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Artistic Design/Influences

• Automotive Design– Appearance– Harmony

• The artistic side of craftsmanship where beauty is in the eye of the customer and sometimes just the designer

• The Artist tries to interpret “The intangible needs of the customer” - “The engineer figures out how to bring it to market”

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Artistic Influences

• Appearance– This is completely the industrial designers’ world– Appearance is highly tied to brand expectations

(especially in automotive)– Designers try to bring the customer a “sense” of

the brand. – Try to see if you can guess what the designer

had in mind on the next slides...

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What Do You Think This Vehicle Looks Like From The Outside? What Is It?

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Audi TT Roadster Detroit Auto Show 2000

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What Do You Think This Vehicle Looks Like From The Outside? What Is It?

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Volkswagen AAC Detroit Auto Show 2000

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Artistic Influences

• Harmony– Do colors, fabrics, and materials match?– Do they blend in a pleasing way?– Does the design draw you towards the

product?– Do you want to spend time with it?

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Harmony? In What Way?

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Contextual Issues

• The same levels of expectations do not always apply to similar products – Engine Compartments (Trucks Vs. Cars)

• Trucks: larger open areas for accessibility (customers typically like to “see the hardware)

• Cars: Covers over components with a “High Tech look

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Contents✓What is Craftsmanship? ✓Influences on Craftsmanship ✓Craftsmanship Motivation✓Design for Craftsmanship Heuristics✓Underhood Craftsmanship✓Assessment Process

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Objective

• Define What Makes Good Craftsmanship

• Understand Why Good Craftsmanship Is Important – Four Pleasures Model

• Add Rigor To The Artistic Side Of Design For Craftsmanship

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Contents

• Characteristics Of Good Craftsmanship• Consumer Interpretation Of Good

Craftsmanship• Impact Of Good Craftsmanship On

Business Equation

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Contents

• Characteristics of good craftsmanship

• Consumer interpretation of good craftsmanship

• Impact of good craftsmanship on business equation

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Simple Design

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Simple Design

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Thunderbird Simple Design

The bumper to fender parting line

has good alignment to the

headlight lens and hood front lip.

Fender contour flows into the headlight.

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Cluttered Design - Relationships Operating

Characteristics

Numerous Added Parts

No Clear Relationships

Airbag Cover Door

Seams

Door Sail

Door Trim To IP

Relationship

Confusing Operation

Complex Relationship

sLarge

Complex Moldings

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Cluttered Design - Relationships

See - Through

Visible Wires

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Cluttered Design

• Number Of Parts

• Cut Lines• See-Through• Relationships• Symmetry

Knee Bolster

PAB Cover

ICP Bezel

Register Bezel

Glovebox Door

IP Substrate

Cluster Bezel

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Surface Finish Choices

• Grain/Texture– Dependant On Manufacturing Process, Material

And Tool Maintenance

• Gloss Level– Dependant On Material, Lighting Conditions,

Grain/Texture And Manufacturing Process

• Color– Dependant On Paint Source,

Grain/Texture/Lighting Conditions And Manufacturing Process

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Material Choices

• Metal• Plastic• Wood• Fabric• Others

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Material Choices

Some Materials Have A Desirable Cachet That Enhances Perceived Craftsmanship (Hardwood Vs. Flakeboard Floors)

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Material Choices

TPO

PVC/ABS

ABS

PVC

Different Materials Can Be Perceived As A Mismatch In Color And Texture

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Case Study - Ceiling Fans

• Examine Two Different Ceiling Fans From A Perspective Of Design For Craftsmanship

A B

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Ceiling Fan - A

Gap Between Blade And Blade Holder Assembly

Consistent Margins Parallel/Concentric With Other Features

Textured Glass Bulb Cover For Improved Light Dispersion And Hidden Imperfections

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Ceiling Fan - A

Gap Between Blade And Blade Holder Assembly

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Ceiling Fan - A

Single Visible Screw To Secure Ceiling Bezel

Clean, Simple Surface Lines For Ceiling Bezel

Tight Margins Between Down-rod And Ceiling Bezel

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Ceiling Fan - B

Large Blade Brackets Bearing Little Relationship To Other Elements Of The Design

Reflective Finish On Lamp Cover Enhances Blemishes And Is Not Fully Integrated

Large Fan Housing Distorts Proportions Of Fan

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Large Black Down-rod Holder Protrudes From Ceiling Bezel

Two Attachment Screws Visible For Ceiling Bezel

Ceiling Fan - B

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Ceiling Fan - B

Gaps Between Lamp Cover And Fan Blade Brackets Are Highly Visible And Detract From Overall Design

Multiple Blade Brackets Increase Number Of Interfaces Between Parts And Are Inconsistent

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Ceiling Fans - Conclusion• Subjective Analysis Suggests That

Ceiling Fan A Represents Better Design For Craftsmanship.

A B

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Simplify, Simplify, Simplify

• Reduced Number Of Parts– Lower Assembly Costs– Fewer Margins To Control– Reduced Tooling Costs

• Eliminate Bezels– Fewer Margins To Control– Reduced Tooling Costs

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Simplify, Simplify, Simplify

• Common Materials– Consistent Gloss Levels– Consistent Color– Consistent Graining

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Simplify, Simplify, Simplify

• Simple Shapes– Reduced Tooling Costs– Easier Margin Control– Coherent Design (Less Whimsical)– Lower Impact Of Environment On

Appearance (Shadows, Etc.)

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Margin and Flushness

Flushness• Due to build variation, manufacturing cannot consistently obtain the perfect theoretical flushness condition• However, variation is known• Also, which flushness condition looks “worse” is also known•Therefore, the vehicle can be built in a nominally underflush / overflush condition so the parts are always assembled in an aesthetically acceptable way

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Margin and FlushnessRoofLiftgate

Under-flush condition

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Margin and FlushnessFlushness – Cheated Panels• Hoods should rigidly remain in their latched position with little to no

flutter• The latched area is designed to pull away from the latch• The areas of the hood bumpers are designed to push into the bumpers• The strut forces are also compensated for

BumperLatch

Hood in Latched Position

Hood As Manufactured

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Margin and FlushnessFlushness – Cheated Panels• Latch-able components like hoods, deck lids, liftgates, and side

doors have a variety of forces being applied to them.• Struts, bumpers, and seals will displace the sheetmetal a given

amount• In order to compensate for this, the sheet metal panel geometry is

manufactured in a “cheated” position• Liftgate struts can have several hundred lbs of force on the liftgate

while in it’s latched positionStrut forces on hatch-back

Liftgate sheet metal is formed in the direction opposite the strut forces to achieve as designed flushness targets

Roof - Body - Strut - Liftgate

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Margin and Flushness

Margins• Margins are varied to give a particular appearance• Margins are not always constant by design

Hood – Fender margin may vary to give a particular appearance.

Headlamp

FenderHood

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Contents

✓Characteristics Of Good Craftsmanship✓Consumer Interpretation Of Good

Craftsmanship✓Impact Of Good Craftsmanship On

Business Equation

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Craftsmanship

• Defined Craftsmanship– Art And Science

• Developed Key Design Themes For Improved Craftsmanship In Automotive Field And Consumer Goods

• Good Craftsmanship Is More Than Just Appearance

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What is Craftsmanship?

As Interpreted By Consumers:– Eyes Of The Customer– Extreme Attention To Detail– Surpass The Limits Of Normal Utility And Functionality– Enter The Dimension Of Art And Beauty– The Art And Execution Of Quality– Perception Of Quality Design– Through Sight, Sound, Smell, And Tactile Senses– Harmony

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Emotional Satisfaction

• Interaction With A Product Derives A Sense Of Emotional Satisfaction For The User.

• Four Pleasures Framework Developed By Anthropologist Lionel Tiger In 1992, And Subsequently Adapted For Use In Design By Patrick Jordan In 1997.

• Analysis Used By Philips Consumer Electronics In Europe.

Jordan, Patrick W And Macdonald, Alistair S; Pleasure And Product Semantics

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Emotional Satisfaction

Sight Sound Touch Smell Taste

PhysiologicalSociologicalPsychological Ideological

INTERPRETATION

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Four Pleasures

• Physiological – Must Appeal To Physical Senses

• Sociological – Improve Interaction With Product/Other Consumers

• Psychological – Must Perform A Needed Function Flawlessly

• Ideological – Must Be Appropriate

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Four Pleasures - Physiological• Pleasure Derived From The Physical Senses.

Includes Tactile Feedback, Operating Efforts, Feel, Smell, And General Physical Interaction With A Product

• Examples:– Bubble Wrap– “Gel” Pen Grip Areas– “New Car” Smell– Balanced Clutch/Accelerator Pedal/Brake Feel– Manual Transmission Shift Feel

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Four Pleasures - Sociological

• Pleasure Derived From The Company Of Others. A Product Which Facilitates Social Interaction Will Be Highly Rated

• Examples:– Internet, E-mail, Chat Rooms– Minivan (Flexible Accommodation)– Baby Intercom System

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Minivan – Flexible Accommodation

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Four Pleasures - Psychological

• Pleasure Gained From The Successful Completion Of A Task Or Goal. A Successful Product Will Help Rather Than Hinder The Achievement

• Examples:– Day Planner– Minivan (Fourth Door)– HP 49G (Ubercalculator)

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Four Pleasures - Ideological

• Pleasure Derived From The Ownership Of A Product Which Symbolizes The Values And Ideology Of The User, As Described By The Brand Personality.

• Examples:– 5 Star Crash Worthiness– Th!Nk Car, Toyota Prius, Honda Insight– Firearms– Motorcycles

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Four Pleasures

• A Good Design Will Stimulate The Senses And Satisfy The Emotions Of The Consumer

• Great Appearance Must Be Reinforced With Outstanding Functionality

• Products Must Be Assessed For Emotional Appeal

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Contents

✓Characteristics Of Good Craftsmanship✓Consumer Interpretation Of Good

Craftsmanship✓Impact Of Good Craftsmanship On

Business Equation

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Improved Brand Equity

• Ford vs. Volkswagen (In Europe)– Ten Years Ago, VW Was In Midst Of Severe

Financial Difficulties– Product-Led Recovery With A Focus On Execution– VW Generally Considered Craftsmanship Leaders

For Mass-produced Vehicles– VW Typically Enjoys 10% Higher Margin Over

Ford Brand Products– One Enabler For VW Has Been Its Ability To

Deliver Vehicles With High Craftsmanship With Only Marginal Cost Penalty

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• Flush Appearance• Improved Feel• Reduced Efforts• Aesthetically Pleasing• Visible Attachments

‘Decora’ Light Switches

• Functionally Identical To Traditional Switches• Material Content Comparable• Premium Of $5-$7 Per Switch

– $550 Cost Per House

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Craftsmanship for Automotive Seats

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Craftsmanship as applied to Automotive SeatsDefinition of craftsmanship from Oxford Dictionary:CRAFTSMANSHIP is the degree of skill in doing a task or of finish in the product made.Craft: skill, ability, ingenuity, art, talent, mastery, expertise, genius, handiwork

The first point of contact between any vehicle and the occupant is the seat. A finely crafted seat invites the customer to sit and experience the comfort and fineness of the seat. A poorly crafted seat does not appeal to the customer, and will cause the potential loss of a sale.

Craftsmanship is an attribute in the design process which targets the customers perception of vehicle quality (fit, finish and execution) and functions designed for user friendliness. It covers what a customer sees, touches, uses and hears.

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Elements of craftsmanship and flow process

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∙ Seats designed with the "clean and neat" look, where the trim cover sew line (style and location) and seat geometry (foam and structure) are well suited for each other;

∙ Seat tracks rounded-off with sleek styling that eliminates or hides sharp edges and covers lubricated surfaces so that fingers can't get pinched and clothes can't be soiled.

∙ Designed attractively; such that side shields may not even be necessary to cover the seat track mechanism.

∙ Operates with low efforts, glides very easily, smooth, quiet and precise.

∙ Mounted in a manner to maximize rear occupant foot and leg room when the seat is adjusted to any position.

Design Guidelines typically employed

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Craftsmanship as applied to Automotive Seats

Seat controls that are: • Located for easy accessibility at any seat

position, with low operating efforts for quick and quiet adjustment.

• Styled to blend in with the surrounding components with no exposed mechanisms or screws.

• Shape and size of controls are user friendly with no accessible underside surfaces that are sharp Have structural ribs or have metal

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Craftsmanship as applied to Automotive Seats

• Seat Craftsmanship is the customer's overall perception of Seat Quality in:

• the consistency of theme ... (what the customer sees)

• the efficiency & cleverness of design ... (what the customer uses)

• the attention to details with the desire to please ... (what the customer touches)

• the robustness and reliability of each component ... (what the customer hears).

• Craftsmanship is hard to measure objectively; but if you see it ... you recognize it.

• What craftsmanship is NOT;It isn't measured by the number of Seat functions or options,or the complexity of manufacturing process used,or the level of technology employed.

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Conclusions• Design For Craftsmanship Checklist

(Simplify, Simplify, Simplify)– Overall Design Theme – Lines/Junctions– Material Choices– Number Of Parts – Part Relationships– Impact Of Environment On

Appearance/Function

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Conclusions

• Emotional Satisfaction– More Than Just Appearance– Must Satisfy The Senses And Emotions

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Conclusions

• Business Equation– Improved craftsmanship can leverage

improved business equation• Increased revenue• Marginal variable/investment cost impact

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Contents✓What Is Craftsmanship? ✓Influences On Craftsmanship ✓Craftsmanship Motivation✓Design For Craftsmanship Heuristics✓Underhood Craftsmanship✓Assessment Process

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Craftsmanship Heuristics

• General Craftsmanship Categories For Vehicles

• Heuristics– Specific– General

• Automotive Examples

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Vehicle Categories• Interior System

– Instrument Panel– Console Assembly– Steering Wheel/Column– Door Trim Panel– Interior Trim– Restraints– Seats– Luggage Compartment

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Vehicle Categories

• Exterior System– Front End– Greenhouse– Rear End– Door System– Decorative System

• Underhood• Night Time Appearance

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Design for Craftsmanship Heuristic

Objective Structure of Product Configuration of Parts

Fasteners Should Not Be Visible

Avoid Fasteners

Hide Fasteners

Cap Fasteners

Color Code Fasteners

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Visible FastenersWrangler

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Visible FastenersEscort

Covered Fasteners Are Better Than

Exposed

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Visible FastenersExplorer Sport Trac

Grab Handle And Trim Fasteners Are Covered Nicely, But Coat Hook Fastener Left Fully Exposed!

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Design for Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Minimize The Number of Margins

Sight Shield

Reduction By Integration

Minimize Parts Coming Into One

Area

Overlapping Surfaces

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Minimize Parts In An AreaChevy Blazer

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An Unsightly Margin…

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A similar Margin Well Presented…

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Sight ShieldDodge Ram

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Minimize Parts In An AreaAudi A3

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New vs. Old

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Overlapping SurfacesAudi A3

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Overlapping SurfacesInstrument Panel

Poor Margins On IP Cluster

Example With Bezel That Covers The

Margin

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Design for Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Avoid Visible Sharp Edges

Sight ShieldReduction By Integration

Overlapping Surfaces Round Edges

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Never Show A Sharp EdgeCherokee

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Never Show A Sharp EdgeAudi A3

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Never Show A Sharp EdgeDeville

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Design For Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Avoid Subtle Differences in Surface Texture and Color

Sight Shield

Reduction By Integration

Greater Differentiation in Texture and Color

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Avoid Subtle DifferencesExcursion

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Avoid Subtle DifferencesLeSabre

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Avoid Subtle DifferencesAudi A3

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Design For Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Optimize Tactile Interfaces

Provide Tactile Consistency

Force/Displacement Curves

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Tactile Interfaces

• Effort• Access• Expectations

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Tactile Effort (Schematic)

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Tactile Effort (Schematic)

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AccessExcursion

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AccessSuburban

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AccessZ3

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Tactile ExpectationAccord

Pushing Here Will Not

Sound The Horn, As

Expected!

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Design for Craftsmanship Heuristic

Objective Structure of Product Configuration of Parts

Optimize audio interfaces

Consistency Retention

Elimination of Undesired Events (Squeak and Rattle)

Frictionless Surfaces

Damping

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Audio InterfacesAudi A3

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Design for Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Minimize surface imperfections

Camouflage Placement of Knit Lines

Material SelectionPlacement of Sink Holes

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Surface Imperfections

• Mold Lines Are The Evidence Marks Left By The Joining Of Two Halves Of A Mold

• Sink Holes Are Left In Injection Molded Plastics Where A Protrusion Exists Beneath The Flat Surface Of A Part

• Gates Are Blemishes In Injection Molded Parts Where The Feeder Tubes Are Removed

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Avoid Mold LinesEscort

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Avoid Mold LinesGrand Cherokee

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CamouflageToyota Sienna vs Lexus RX 300

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Design for Craftsmanship Heuristic

Concrete Measure

Objective Structure of Product Configuration of Parts

Craftsmanship is Often Product Dependent

Flexible Platform Strategies

Component Differentiation

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Product DependenceCavalier

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Product DependenceMercedes S500

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Product DependenceSuburban

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Mustang: Wrong Direction over Time?

• Cost And Craftsmanship May Correlate• The Following Is A Comparison Of

Some Exterior Mustang Craftsmanship Issues (1994-2002)

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1994 vs 2002 Mustang

Brake Light Is Incorporated Into The Spoiler Providing A “Clean” Appearance. Taillight Modules Color Matched To Body. Common Theme Of Smooth Horizontal Lines.

Door, A-pillar, Quarter Panel Intersection Is Smooth Due To Painted Mirrors And Panel Design.

Redesigned Quarter Panel And Unpainted Mirrors Emphasize Gaps And Incongruent Fit.

Functional Air Vents For Improved Aerodynamics As Well As Styling.

Non-functional Painted Plastic Appliqués Are Subject To Quality And Durability Concerns.

Brake Light Is 3X Larger And Incorporated Into Trunk. Tail Light Modules, Fascia Perforations And Cut Lines Do Not Appear To Have A Common Stylistic Theme.

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In The 2002 Model, The Door Handle Is An Extremity To The Body Side. The 1994 Model Is Recessed And De-emphasized As Captured On The Previous Slide.

The “Cut Lines” Within Each Stamping Do Not Match Up With The Interfaces Between Body Panels. In Example A The Relationship Of Quarter Panel To Fascia Appears To Be Incongruent. In Example B, Hard Lines Caused By The Accentuated Fender Lip Break The Cut Line That Travels The Length Of The Body.

A

B

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A Final Heuristic: Hide the Ugly!

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Contents✓What Is Craftsmanship? ✓Influences On Craftsmanship ✓Craftsmanship Motivation✓Design For Craftsmanship Heuristics

✓Underhood Craftsmanship ✓Assessment Process

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Examples Of Average Craftsmanship

• Poor Coordination Of Hoses And Wirings• Exposed Hardware And Mechanisms• Busy Appearance

Positive Aspects

Negative Aspects

• Color Coordination Of Service Bottles Caps (Fiesta)

Fiesta

Honda CRV

( )

( )

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• Wires And Hoses Not Coordinated• Visible Part Number Labels

Positive Aspects

Negative Aspects

• Clean Appearance Of Major Parts Covers (Air Filter, Battery, Etc.)

Fiat Palio

Examples Of Average Craftsmanship ( )

( )

Ka

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Examples Of Good Craftsmanship

• Appearance Of Colored Wires• Hood Lock Mechanism Exposed

Positive Aspects

Negative Aspects

• Covered• Brand Badge With Good Appearance • No Visible Supplier Labels• Clean Appearance Of Covers

Peugeot 206

VW Gol

( )

( )

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Examples Of Excellent Craftsmanship

• Clean Appearance• Covered• Hoses And Wirings Coordinated• Engine Type And Brand Highlighted• Location Of Oil Dipstick• Bottles And Caps On Outer Sides

Positive Aspects

Audi A6

VW Golf

( )

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Examples of Bad Craftsmanship

Negative Aspects ( )• Washer bottle cap poorly located, hose on reach zone and no clearance to fender edge• Oil dipstick located close to heat area (exhaust manifold)• Screws with different color of background

Peugeot 206

Peugeot 206

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Examples Of Good Craftsmanship

Peugeot 206

Peugeot 206

• Fresh Air Hose For PVC Well Executed • Fuse Panel; Good Appearance Of Cap With Graphics Embossed, Good Fit Of Wiring Harnesses To Cap

Positive Aspects ( )

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Examples Of Good Craftsmanship Positive Aspects ( )

• Battery; Located Square With The Engine And Other Components• Good Appearance Of Cover And And Fit To Other Components• Hood Prop Rod; Not On Reach Zone For Servicing Engine Compartment

Peugeot 206

Peugeot 206

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Examples Of Bad Craftsmanship

Negative Aspects ( )

• Part Label Exposed And Poorly Attached• Washer Bottle Cap; No Clearance To Fender Edge, Possible Hand Injuries

Fiesta

Fiesta

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Examples Of Good Craftsmanship Positive Aspects ( )

• Hood Prop Rod; Covered, Color Coordinated And No Paint Chips At High Time In Service Due To Plastic Attachment• Hood Secondary Release Touch And Feel Area; Covered (But With Exposed Mechanisms)

Fiesta

Fiesta

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Examples Of Bad Craftsmanship

Negative Aspects ( )

• Big And Not Centered Latch• Different Color Highlights Part On A Dark Background

Fiat Palio

Fiat Palio

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Contents✓What is Craftsmanship? ✓Influences on Craftsmanship ✓Craftsmanship Motivation✓Design for Craftsmanship Heuristics✓Underhood Craftsmanship ✓Assessment Process

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Assessment Process

• How Do You Measure Craftsmanship?– Determine Attributes Of Product To Measure– Use A Weighted Average Assessment Scale

• Weighting Of Attributes: 0-5 – (0 – Unimportant, 5 – Important)

– Evaluate Product Against Attributes: • Scoring Of Product: 0-6

– (0 – Worst, 3 – Industry Average, 6 – Best)

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Assessment Process

• Is It Best Performed By One, The Few Or The Many?– Because Of The Subjectivity Involved, It Is Best

Performed By As Few People As Possible– They Should Remain Autonomous To Minimize

Influences– They Perform The Analysis Of The Entire Industry

Under Review For Consistency– They Are “Trained Eyes” That Know What To Look

For, Know What The Customer Expects, And Know How Much Weight To Apply To It

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Assessment Process

• Let’s Try An Example

• Underhood Of A Vehicle

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Perceptions Count

• Underhood appearance is good or bad, depends on your opinion. • VW and BMW can have great underhood appearance, but very few see

or care from experience. So is poor underhood appearance worth effort and (yes the BMW level costs money) worth it? Plastic covers are compromise to hide things. A functional snow pack shield or NVH dampening cover is sometimes justification for “craftsmanship”.

• The GTDI twin turbo engine is as much an NVH cover as an appearance cover for a great performance engine!

12/26/13 MPD575

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Assessment Process

• The Coordination Of Hoses And Wiring Routings Is The Attribute Of Interest

• Subjectively, This Attribute Is Assigned A Weighting Factor Of 5

• Each Car Is Rated From 1 (Poor) To 6 (Superb)

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Assessment Process

• What Is The Score?– Few Hoses Visible– Layout Seems

Somewhat Well Thought Out

– Coolant Recovery Hose Seems To Just Lay Across Everything Else

• Score: 3Car #1

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Assessment Process

• What Is The Score?– “Bunch Of Snakes”

Look– Hoses Not

Coordinated– Hoses Just Laying

On Top Of Other Parts

• Score: 2 Car #2

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Assessment Process

• What Is The Score?– Few Hoses Visible– Layout Seems

Somewhat Well Thought Out

– Red Wires In Middle Highly Detract From Overall Look

• Score: 4 Car #3

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Assessment Process

• What Is The Score?– “Bunch Of Snakes”

Look– Hose/Wire Routing

Not Coordinated– Hoses Just Laying

On Top Of Other Parts

• Score: 1 Car #4

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Assessment Process

• What Is The Score?– Few Hoses Visible– Layout Seems

Somewhat Well Thought Out

– Hose/Wire Routing Is Neat And Organized And Parallel To Each Other

• Score: 5Car #5

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Assessment Process

• What Is The Score?– Very Few To No

Hoses/Wires Visible– Layout Seems Very

Well Thought Out

• Score: 6Car #6

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Assessment Process

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Assessment Process

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Assessment Process• Total All Attributes

• Highest Score Shows The Best Vehicle

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Assessment Process Summary

• Try To Find The Areas Of Craftsmanship That The Customer Values Over The Others And Spend Time And Money In Perfecting These Items

• These Expenditures Can Be Decreased By Using Carry-over Parts That Are Known To Achieve High Craftsmanship Ratings

• Do Not Spend Time And Money On Items The Customer Does Not Value Or Cannot See

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Assessment Process

• High Craftsmanship Value Parts– Extra Efforts Are Spent In

Perfecting The Surface, Color, And Texture Of An Instrument Cluster, Because It Is Something The Customer Always Sees When Operating The Vehicle

Hubs Cover Interface Between

Stationary And Moving Parts

Mask Covers Edges Of Appliqué

Fonts Are Large,

Clear And Easy To

Read

Grains Hide Imperfections

In Molding Process

Poor Alignment

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Assessment Process

• Standard Craftsmanship Parts– Efforts Are Spent To

Select A Material And Apply A Texture That Allows Operation In The Coldest Of Temps While Not Showing Finger Prints For Security Reasons Allows Tactile

Feedback

Backlit For Operation In Low Levels Of Light

Bezel Provides A Clean, Smooth Edge

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Assessment Process

• Low Craftsmanship Value Parts– This Electronic Module Is

Packaged Behind The Trim And Is Not Visible To The Customer. Minimal Efforts Were Applied In Perfecting The Surface, Color Or Texture Of This Housing

Material Flow Swirl And Sink Marks

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Assessment Process Conclusions

• Spend Additional Resources On Parts And Interfaces That Have High Customer Value

• Spend Little Resources On Parts And Interfaces That Have Little Customer Value

• It Is All A Trade-off In The End And The Law Of Diminishing Returns Is In Effect

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Contents✓What is Craftsmanship? ✓Influences on Craftsmanship ✓Craftsmanship Motivation✓Design for Craftsmanship Heuristics✓Underhood Craftsmanship✓Assessment Process

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A Final Warning

• Some Craftsmanship Choices May Impact Other Engineering Trade-offs– Underhood Beauty Cover Impacting Air

Flow And Heat Management– Fountain Pen Material Choice Will Impact

Cost And Fabrication Technique (Wood vs. Plastic vs. Metal)

Page 173: Design For Craftsmanship MPD575 DFX Jonathan Weaver.

Other DFC Considerations

• Certain vehicle components, if replaced, could cause collateral damage to adjacent systems that depend on the component in OEM form.

– Example: Underbody shield with cooling ducts being replaced with a skid plate using no ducts can result in overheating

• The designer should use caution when selecting fasteners.

– Joints or components which must not be tampered with need to either• A: Eliminate the joint/interface• B: Use fasteners which cannot be removed by common tools• C: Use one-way fasteners• C: Prevent the user from disassembling the system down to the

component level (Ex: use press fit on a water pump shaft to prevent replacement with a substandard part)

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References• The American Society of Mechanical Engineers, ASME Y14.5M-

1994, 1995• Poka-Yoke information

http://www.campbell.berry.edu/faculty/jgrout/textonly.html • Jordan, Patrick W and MacDonald, Alistair S; Pleasure and

Product Semantics

• Zero Quality Control: Zero Source Inspection and the Poka-Yoke System, Shingo, Shigeo. 1986 translation, A.P. Dillion, Portland, Oregon: Productivity Press.

• A good source of information: http://www.campbell.berry.edu/faculty/jgrout/textonly.html

• A good source of bad information: http://www.baddesigns.com/

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References• BV Platforms Craftsmanship Guidelines, Amazon

Underhood, M. Longuinho, 7-28-2000. Provided by L. Weitman, Cohort 2 with permission to use here.

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Design for Craftsmanship

Questions ??