1. MANAGEMENT TOOLS
• PLM: PRODUCT LIFECYCLE MANAGEMENT
• TQM: TOTAL QUALITY MANAGEMENT
1
Designing & Engineering
Operations to Run with
Accuracy & Consistency of a Clock
DEVELOPMENT TOOLS:
• CONCURRENT ENGINEERING
• DFX: DESIGN FOR EXCELLENCE
BY: MAHZAD PAKZAD, MAY 31, 2016

2. So you are going to rely on
what/whom to deliver
results?
MANAGEMENT TOOLS:
• PLM: PRODUCT LIFECYCLE MANAGEMENT
• TQM: TOTAL QUALITY MANAGEMENT
DEVELOPMENT TOOLS:
• CONCURRENT ENGINEERING
• DFX: DESIGN FOR EXCELLENCE
Dilemma:
Production
people are
going to figure
out the details,
they always
have!
2

3. The KEY is in having Experienced, &
Conscientious Technical People, with ability to
explain the need for innovative, cost effective
solutions, working as leaders in your teams!
The Boeing 787 Dreamliner is an example, where high level management tried to cut costs, using Tools like
Concurrent Engineering, DFX, and PLM, but it failed to sell its reasons to its employees, and therefore,
ended up with Quote:
“All in all, 70 percent of the 787 is being manufactured outside the United States, up
from less than 2 percent for the 747 in the late 1960s. A reasonable guess — if one that Stewart stops short
of suggesting — is that Boeing is going the way of Zenith, General Motors, and other erstwhile American
industrial titans that have had their clocks cleaned in East Asia. - See more at: http://
www.airlineupdates.net/the-boeing-787-the-truth-finally-hits-the-fan/#sthash.QmTdcCyA.dpuf”
The writer of the above quote does not know that Boeing’s managements’ original plan included a
major labor reduction (quite higher than the one implemented), & quality improvement, using
automation, DFX, & PLM, but it was opposed/sabotaged by employees who were there to
implement the plan, may be just because they did not know how to implement it, but they
changed the plans by playing games, and as the result Boeing kept going to subcontractors for
sourcing subassemblies cost effectively, in addition to sourcing parts!
Designing & Engineering
Operations to Run with Accuracy & Consistency of a Clock
3

4. Or what do you think would happen, if
the body components were formed and
designed to function without DNA/
Genetic mapping, or if there were
connection & communication gaps
between your nervous system and
brain?
or
What if our bodies did not have the
capability to adjust and adopt to
environment?
Imagine!
What if the components in our body were operating without a
central nervous system that was controlled by a single brain!
4

5. In a nutshell, we need to have:
❖ Systematic planning, ie: Market Analysis, Product Benchmarking,
Technology Benchmarking, for Defining Quality Expectations; these
are Methods & Tools that Set The FOUNDATION, & “Enable”
Identification and Control requirements for major functional units,
including design, and manufacturing, as well as supplier quality.
❖ Experienced Designers and Engineers, & adequate hight tech tools to
both Identify & Set Standards and Specifications for building
innovative and cost effective products; Concurrent engineering
supports working together, assuring Alignment of Both Design &
Manufacturing Specifications with Customer/Market Needs.
❖ Thorough Cultural Trainings, educating people for building
Confidence, Trust & Respect to support proper execution of plans is
critical; So is positive/proper team communication for maximizing the
effectiveness of teams working together, while developing solutions,
with focus on delivering Quality outputs, consistently, cost effectively!
5
Designing & Engineering
Operations to Run with
Accuracy & Consistency of a Clock
Dilemma: Production people are going to figure out the details,
they always have!
MANAGEMENT TOOLS:
• PLM: PRODUCT LIFECYCLE MANAGEMENT
• TQM: TOTAL QUALITY MANAGEMENT
DEVELOPMENT TOOLS:
• CONCURRENT ENGINEERING
• DFX: DESIGN FOR EXCELLENCE

6. PLM PHILOSOPHY
6
The purpose of all popular PLM software is to
provide one single tool to define & manage all
elements that contribute to manufacturing
products from the conception through sale of
finished goods.
THE PURPOSE OF HAVING A SINGLE TOOL TO
MANAGE ALL, IS TO “ALIGN ALL
SPECIFICATIONS, INPUTS/OUTPUTS”, AND
MAKE SURE THAT ALL BUSINESS UNITS ARE
DESIGNED AND OPERATE TO DELIVER TO
CUSTOMER SATISFACTION, COST
EFFECTIVELY!
Total Quality Management, is the Philosophy that supports analyzing all factors that are
inputs to processes, and influence quality of the products, in order to assure Successful
Quality Management.
TQM SUPPORTS SUCCESS OF PLM!
DFX
MARKET
RESEARCH
CONCEPT
DEV.
D & D
MANUFACTURING
SALES &
SERVICE
CONCURRENT ENG.
PLM
SUPPLY
CHAIN
TQM

7. 7
PLM PHILOSOPHY
Dilemma: Production people are going to figure out the
details, they always have!
DFX
MARKET
RESEARCH
CONCEPT
DEV.
D & D
MANUFACTU
RING
SALES &
SERVICE
CONCURRENT ENG.
PLM
SUPPLY
CHAIN
TQM
MARKET RESEARCH SUPPLY CHAIN
DESIGN &
DEVELOPMENT
MANUFACTURINGPRODUCT
CONCEPT DESIGN
SPECS
PHYSICAL
FUNTIONAL
SPECS
USER
INTERFACE
SALES & SERVICE
USER
DEMANDS
Type of product
volume
quality expectations
FLEXIBILITY
life expectancy
STRATEGIC
PLANNING
DESIGN
FOR
EXCELLENCE
INNOVATIVE DESIGN IDEAS,
Critical To Quality SPECS;
SPECIAL PROCESSING SPECS;
PROTOTYPING/CONCURRENT ENG.
(DFM, DFA, DOE,.FMEA,DFMEA,…)
SOURCING/FABRICATION/
CAPABILITIES/CAPACITY
FEASIBILITY STUDIES
PRODUCTION
ENGINEERING
METHODS /PROCESSES EVALUATION
QUALITY/CAPACITY SPECS
AUTOMATION FEASIBILITY/JUSTIFICATION
FACILITIES MANAGEMENT
MATERIALS MANAGEMENT
STRATEGIC
PLANNING
SALES/REPAIR/CUSTOMER TRAINING
STRUCTURED REPAIR/
SERVICE PLANNING
WAREHOUSING STRATEGIES
QUALITY
COST
VOLUME
MANAGEMENT TOOLS:
• PLM: PRODUCT LIFECYCLE MANAGEMENT
• TQM: TOTAL QUALITY MANAGEMENT
DEVELOPMENT TOOLS:
• CONCURRENT ENGINEERING
• DFX: DESIGN FOR EXCELLENCE

8. 8
Dilemma: Production people are going to figure out the details, they always have!
MARKET RESEARCH SUPPLY CHAIN
DESIGN &
DEVELOPMENT
MANUFACTURINGPRODUCT
CONCEPT DESIGN
SPECS
PHYSICAL
FUNTIONAL
SPECS
USER
INTERFACE
SALES & SERVICE
USER
DEMANDS STRATEGIC
PLANNING
DESIGN
FOR
EXCELLENCE
PRODUCTION
ENGINEERING
STRATEGIC
PLANNING
• TYPE OF
PRODUCT
• VOLUME
• QUALITY
EXPECTATIONS
• FLEXIBILITY
• LIFE
EXPECTANCY!
• CUSTOMER
NEEDS
• QUALITY
• COST
• VOLUME
• FABRICATION
CAPABILITIES
• CAPACITY
• FEASIBILITY
STUDIES
• SOURCING
• INNOVATIVE
DESIGN IDEAS
• CRITICAL TO
QUALITY SPECS
• SPECIAL
PROCESSING
SPECS
• PROTOTYPING
• CONCURRENT
ENG.
• DFM, DFA, DOE,
FMEA,DFMEA
• METHODS /
PROCESS
CONTROLS
• QUALITY/
CAPACITY SPECS
• AUTOMATION
FEASIBILITY
• JUSTIFICATION
• FACILITIES
MANAGEMENT
• MATERIALS
MANAGEMENT
• STRUCTURED
REPAIR &
SERVICE
PLANNING
• SALES/REPAIR
CUSTOMER
TRAINING
• WAREHOUSING
STRATEGIES
CONTROL OVER PRODUCTS’ QUALITY AND COST HAS
REQUIREMENTS BEYOND SOFTWARE CONTROLLED TASKS

9. DESIGNING & MANUFACTURING PRODUCTS THAT USE HIGH TECH MATERIALS
AND PROCESSES ARE AS COMPLICATED AS ONE OUGHT TO EXPECT THEM TO BE!
Materials that need to deliver products within expected accuracy and
reliability need to:
❖ Have the right classification for purity & consistency.
❖ Be processed accurately, within tolerances that their chemical/physical properties
demand it!
Equipment that need to deliver products within expected quality and
reliability need to:
❖ Be carefully designed with upfront knowledge of Input Variations as well as requirements
for Output Quality & Quantity.
❖ Have both right component quality, “Controlled Range” of flexibility, and proper system
integration, in order to produce cost effective quality parts, consistently.
Management who run operations that utilize high tech Materials &
Processes, need to:
❖ Be able to relate Market/Customer needs, to the CTQ within their business units.
❖ Have capabilities to set up teams that can deliver reliable products’ and processes
specifications & have technical know how to manage them, and change them as
required!
The major tools that, when utilized by skilled people, ethically, can support Cost Effective
Production of Quality Products, effectively:
DEVELOPMENT TOOLS:
• CONCURRENT ENGINEERING
• DFX: DESIGN FOR EXCELLENCE
MANAGEMENT TOOLS:
• PLM: PRODUCT LIFECYCLE MANAGEMENT
• TQM: TOTAL QUALITY MANAGEMENT
9

10. 10
DFX CALLS FOR UP FRONT EVALUATION OF THE ENTIRE PRODUCT
LIFECYCLE, FOR IDENTIFYING PARTS/OPERATIONS’ REQUIREMENTS, IN
ORDER TO SET UP MANUFACTURING OPERATIONS THAT CAN DELIVER
THE EXPECTED CUSTOMER DEMANDS, COST EFFECTIVELY!
Reliability of Quality &
on Time Availability
Cost of
Fabrication
Cost of Assembly
Cost of Production
Control
Product
Functions
Cost of Materials
Handling
Raw Materials
Cost
Design
Innovation
Capital Investment for
Production Cost of Service
Capital Investment for
Facilities
Cost of Facilities
Management
ONE TIME INVESTMENT
COSTS
DAILY OPERATIONS
COSTS
CUSTOMER NEEDS
UPFRONT CONCURRENT
ENGINEERING WILL SUPPORT
SUCCESS OF DFM, DFA, & OTHER
COMPONENTS OF DFX

11. SYSTEMS ENGINEERING
PHILOSOPHY
MATERIALS
SCIENCE
PROJECT MANAGER
DESIGNER
ENGINEER
PROBLEM SOLVER
OPERATIONS
MANAGEMENTPREVENTIVE
MAINTENANCE
STRATEGIC
PLANNING
TECHNOLOGY
TRANSFER
TRAINING
11
Designing & Engineering Operations to Run with
Accuracy & Consistency of a Clock
MAHZAD PAKZAD
IT’S NO
SECRET TO THOSE WITH EXPERIENCE, YOU
NEED MULTI-SKILLED AND HIGH TECH PROFESSIONALS TO HELP THE
TEAM WITH MAKING THE RIGHT
DECISIONS!