Document Type


Date of Award

Fall 1-31-1996

Degree Name

Master of Science in Manufacturing Systems Engineering - (M.S.)


Industrial and Manufacturing Engineering

First Advisor

Sanchoy K. Das

Second Advisor

Layek Abdel-Malek

Third Advisor

R. S. Sodhi


The competitive nature of modern manufacturing, demands that innovative approaches be applied in order to have a competitive edge. Shortening the product development cycle, the period from initial design to full production, is a priority for most manufacturers today. The DFQM methodology addresses the issue of quality manufacturability (QM) - the likelihood that defects will occur during manufacture of a product in a standard plant. As a consequence, DFQM helps to shorten the design cycle time. The DFQM architecture identifies a variety of design factors and variables that influence specific defects. This process of influencing defects can be described by error catalysts.

This thesis presents the design of the error catalyst associated with two classes of defects, which are total nonconformity and damaged parts. Error catalysts are described in the form of catalysis graphs. Each catalysis graph leads to an index between "0" and "I", based on the factor variables for the given design, implying the likelihood of occurrence of that specific defect. The overall QM Index of a design is derived from these values. The error catalysts associated with defect class total nonconformity helps to identify features in design that results into poor quality product when it is assembled. The error catalyst associated with defect class damaged parts, helps to introduce rigidity and optimize aesthetics in product.

The DFQM analysis is then applied on an example product to illustrate the practical feasibility of the methodology.

Included in

Manufacturing Commons