Design For Quality is a process we follow in order to design good quality into products at the early concept and prototyping stages during the new product introduction process.
You will probably be surprised as to how many design points need to be considered in order to have a mature product design that can be mass-produced with the minimum of quality problems, defects, safety issues, and more.
Our CEO Renaud has worked with clients on numerous products over around 2 decades in Asia and performing thorough DFQ reviews on their product designs is one of the key tools in Sofeast's armory when it comes to bringing great quality products to market. So, in this episode, he shares the lowdown on this important quality process.
Show Notes00:00 - Introducing the episode
01:14 - Why is the design stage of the new product introduction process so important? - Renaud gives a lot of background about what goes into product design and how the decisions you make about materials and processes impact product quality (considering 'what could go wrong based on what we know about them?'). Also, he explains the difference between manufacturing quality issues and design deficiencies.
09:14 - DFQ reviews often happen before you invest in the tooling. Here's why... - Tooling is very expensive, so making changes to the design before it's made is really preferable, but most Chinese manufacturers are not good at providing feedback on designs that can cause costly manufacturing issues (like scrap and rework).
11:30 - Changes are quick and cheap at the concept stage, but later on are an expensive problem - Renaud discusses this point which is also illustrated in this graph:
14:30 - What are the principles in DFQ that we follow when reviewing our product and its design?
24:11 - If you're manufacturing a new product, who can you rely on for information about your product at an early stage? - Manufacturers often say that they do a DFM/DFQ review, but they don't always take it very seriously. So a common concern is how reliable the review was. Therefore many importers choose to work with a specialist 3rd party engineering firm to help them perform a DFM review and assist with their product R&D (our company Sofeast is one example) in addition to their manufacturer.
27:32 - Some common mistakes that cause poor-quality products (that we try to weed out with a DFQ review):
36:58 - Some examples of how DFQ reviews have improved products before they went into production - since this is something we actively do, Renaud shares some real-life examples, and more. Includes hazardous battery design (think Note 7), brittle magnets, products that need to be waterproof, and more.
39:54 - You may get helpful feedback from component/material sub-suppliers - good feedback can be found by forcing a dialogue with sub-suppliers which Chinese manufacturers may not do in their haste to go to mass-production. But if these sub-suppliers are specialists in the component or material in question they may have some very helpful advice about how the product design best makes use of the component/material in order to reduce quality issues during production.
40:47 - Wrapping up
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