Computer-Aided Systematicity in the Development of Heavy Trucks: From Design to Production

This paper will demonstrate an integrated approach to product development and documentation using IQ-FMEA quality software¹. This approach begins with the creation of a system structure and assigning functions or requirements to these structural elements; the structure is subsequently expanded through the incorporation of potential failures which are linked to these functional requirements. This expanded system provides the necessary inputs for the development of structurally-linked cause-effect function and failure networks which can be transferred directly and automatically into Design Failure Modes and Effects Analysis (DFMEA) forms. Data can easily be selected from DFMEAs or underlying structures to create Process FMEAs (PFMEAs) using Drag & Drop technology. Risk ratings catalogs facilitate consistent application of criteria for ranking potential failures in the FMEAs; basic statistical analysis and sorting options aid designers and quality specialists in assessing strengths and weaknesses of current designs or processes and in prioritizing detection and avoidance actions. Responsibility and deadlines assigned to individuals or teams and options for the display of various revision states allow for easy tracking of progress throughout the development process. Such re-use of information and prioritization of objectives represent substantial time savings.

Integration of functions and potential failures into an overall structure provides an underlying system which can be modified as design aims change or when a product is to be updated. In addition this system provides a framework for the organization of design and quality controls. Supplied components structures, in addition to corresponding FMEAs, can be incorporated into this system for greater control of the end product. The conscientious application of this method supported by of a fully integrated and easily up-datable database achieves goals of consistency and systematicity throughout the product cycle.