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"A thoughtful, complete, and very readable approach to robust engineering. It presents insights that correlate with those learned at Ford while developing and executing Design for Six Sigma. Having this book three years ago could’ve helped with that effort."–David Amos, DFSS Deployment Director, Ford Motor Company Written by Anna C. Thornton, the well-known author who coined the phrase "variation risk management," this comprehensive book presents new methods and implementation strategies based on her research of industry practices and her personal experience with such companies as The Boeing Company, Eastman Kodak Company, Ford Motor Company, Johnson & Johnson, and many others. Step-by-step guidelines show how you can implement and apply variation risk management to real-world problems within the existing systems of an organization.
Companies and academics have known for many years that reducing variation in production processes can decrease production cost, increase product quality, and have substantial impact on overall profitability. Tools to help companies track, assess, and improve variation are numerous and readily available, but gradually an understanding has emerged from implementing these tools that significant amounts of variation cannot be removed from the factory, and the only way to continue to improve cost and quality beyond diminishing returns is to move upstream in the process and design parts and assemblies that are more variation resistant, or maintain quality functionality over a broader range of variation. One methodology emerging to help companies with this task is Variation Risk Management (VRM). The problem with VRM and other methodologies is that they are often treated as side processes that do not get well integrated into the overall product development process. This results in training and improvement activities that optimize VRM on its own rather than maximizing the effect VRM has on the product. In order to do this the initiative failure cycle must be understood, and attention must be focused on information management, management and organizational support, and process like communication and integration.
(Cont.) This thesis addresses the challenges of variation risk management encountered during an internship at Raytheon Company, and presents a unique solution for overcoming a lack of information regarding Key Characteristic variability. Once information is obtained, analysis is conducted to assist with identifying trade-offs and making program-level decisions. Although many problems presented are unique to Raytheon Company, the concepts can be applied across a wide range of manufacturing industries.
Risk assessment has become a dominant public policy tool for making choices, based on limited resources, to protect public health and the environment. It has been instrumental to the mission of the U.S. Environmental Protection Agency (EPA) as well as other federal agencies in evaluating public health concerns, informing regulatory and technological decisions, prioritizing research needs and funding, and in developing approaches for cost-benefit analysis. However, risk assessment is at a crossroads. Despite advances in the field, risk assessment faces a number of significant challenges including lengthy delays in making complex decisions; lack of data leading to significant uncertainty in risk assessments; and many chemicals in the marketplace that have not been evaluated and emerging agents requiring assessment. Science and Decisions makes practical scientific and technical recommendations to address these challenges. This book is a complement to the widely used 1983 National Academies book, Risk Assessment in the Federal Government (also known as the Red Book). The earlier book established a framework for the concepts and conduct of risk assessment that has been adopted by numerous expert committees, regulatory agencies, and public health institutions. The new book embeds these concepts within a broader framework for risk-based decision-making. Together, these are essential references for those working in the regulatory and public health fields.