The application of Quality Function Deployment to the design and manufacture of engine main bearings

Abstract

Quality Function Deployment is an extremely useful tool which can be applied within the Systems Engineering Process, to optimize product design and the design process. The use of cross functional teams to analyze customer needs; translate them into design attributes; and subsequently deploy them through every facet of product design, development, and production, can significantly enhance the effectiveness and efficiency of the entire process. Unfortunately the few examples of Quality Function Deployment application, in the academic literature, are generally simplistic and lack any significant depth. The objective of this report is to investigate the application of Quality Function Deployment to a relatively complex product design requirement in an actual manufacturing environment. Specifically, the design and production of engine main bearings at the Federal Mogul plant in Blacksburg, Virginia, are considered. The report examines the use of Quality Function Deployment, as a general design tool; the functional requirements and design constraints of engine main bearings; and the application of one variation of Quality Function Deployment to the evaluation of proposed changes to a bearing's design configuration and the bearing production process. The report concludes with recommendations concerning the implementation of Quality Function Deployment at Federal Mogul, the conduct of Quality Function Deployment instruction at Virginia Tech and a possible avenue for future research.