Compact Air Controller
Developed by QFD and TRIZ
Shinwa Controls Co., Ltd.
Kenji Nishimura, Masakazu Kuroki
Mayumi Ikeda, and TakujiYamamotoToday’s Agenda• Corporation Profile• Objective of This project• Outline of This Project• Accomplishments of This Project• Future Plans

Corporation Profile Company Name: Shinwa Controls Co., Ltd.
 Found: June 21, 1962
(As Shinwa Industry Co., Ltd.) Establish: December 15, 1967
 Capital: JPY 50 million.
 Business Contents: Design, Development, Manufacture and Sale for Precise
LiquidTemperature Equipment, Precise Temperature & Humidity
Equipment, and Solenoid Valve Number of Employees: 281 (As of June 31, 2012)
 Affiliates: Shinwa Technos Co., Ltd.
Shinwa Controls Taiwan Co., Ltd.

Corporation Profile
Business Locations in Japan
Headquarters: Asaoku Kawasaki-city, Kanagawa
Kyushu Plant: Omura-city, Nagasaki
Nagano Plant: Ina-city, Nagano
Kumamoto plant: Yamae-mura Kuma-gun, Kumamoto
Osaka Sales Office: Osaka-city, OsakaCorporation Profile
Product Lineups
Development of equipment to precisely control gas (air) and liquid (fluids such as water, chemicals,etc.) .

Solenoid Valve
Motor Valve
Air Temperature andHumidity Controlequipment
Liquid Temperature
Control Equipment(Chiller)

Corporation Profile
Temperature Air/Liquid-Supply Controlling Equipment• Our equipment controls on temperature and humidity
which are both required in manufacturing processes
related to semiconductor and FPD.
• .

Objectives for This Project• It’s uncertain that the customers’ needs meet ourdevelopment point in the aspect of coordination.
• The scope of idea or conception could be quite shallow
upon the problem concerned.

In order to break this current situation, apply theQFD and TRIZ, develop the innovative productwhich meets customer needs.

Objectives for This Project
Target: Break Away from Order-Taking Business.

Consulting withIDEA Inc.
1. QFD：Listen Up Customers’ Voice.
2. TRIZ：Obtain Innovative Ideas.
3. Commence the Development→ Make It a Product.

Outline of This Project
Policy Committed
1. Make the Entire Development Process Efficient.
- Introduce the QFD and TRIZ.
2. Resolve the Issue of “Superior Pure Air SupplyEquipment” which is One of the Main Products at theKyushu Plant.
3. Spread the Contents of This Project Company Wide.
4. Apply the Knowledge and Experience of Instructors
from Outside the Company.

Outline of This ProjectThe Process and Development Plan
実施Step①Introductory3Hr①TRIZ導入啓蒙講演(ｷｯｸｵﾌ、必要性の認知)Educationof TRIZ: 3hr：受講者数②Educationof QFD: 1 day③Selecting theme③QFD課題抽出テーマ選定(有用な効果を狙ったﾃｰﾏ検討)
using
QFD
：受講者数

②QFD基礎教育1日間(3日ｺﾝｻﾙを前提とした基礎教育)：受講者数④Educationof TRIZ: 2 days

④TRIZ基礎教育2日間(7日ｺﾝｻﾙを前提とした基礎教育)：受講者数⑤Problem Solving
using TRIZ: 7days⑤TRIZ実務ﾃｰﾏ解決ﾌﾟﾛｸﾞﾗﾑ7日間(実ﾃｰﾏ解決取り組み)
：テーマ数

⑥設計
(構想設計、詳細設計<ﾊﾞﾗｼ含む>)⑦組立・検証・出荷

６月

７月

８月

２０１０年
９月
１０月

１１月 １２月

１月

２月

３月

４月

２０１１年
５月
６月

７月

８月

９月

Outline of This Project
QFD Fully Follow Up
Day 1① Collect Requirement Sources from Customers.
② Sort Out Quality Requirements.
Day 2① Draw the Quality Requirement Sheet.
② Consideration in Quality Control Dept.
③ Extract the Quality Characteristic, andDraw a Spread Table.
Day 3① Draw up the Duality Chart for Quality Requirement andCharacteristic.
② Consideration in Quality Design Dept.
③ Find Out Technical Issues (to Check.)④ Confirm with Applying TRIZ.

Outline of This Project
QFD: Quality Table
品質特性
遮音性騒音

耐熱熱対策

電気の遮断特性機器の分解能ダ
ク
ト
長ダ
ク
ト
形
状

ダ
ク
ト
断面
積部
品の統
一部
品の共
通化

部
品
交換
性

11負
荷率

開
閉
回
数

サ
イズ

余
裕
度

組
立
性

メ
ン
テ
性

2111

111

構
造

汎
用
性
・共
通化

操
作
性

風量
自動調
整流量
自動調
整

冷
凍機
自動調
整ユ

空調・液調

素人でも)))()()

温度の制御精度が高い

冷却能力が優れている 冷却能力の範囲が広い
風量範囲
低風量を供給出来る
大風量を供給出来る
使用する風量に幅があ
低～大風量まで供給出来る起動時間／安定時間○ ○ ◎ ○ ○ ○ ○ ○ ○ ○ ○

○ ○ ○

◎○

起動時間が短い待ち時間が短い
離れた場所・ポイントの制御が出来る

応答性が速い
環境の変動に追従で変動を減衰出来る
きる
周囲の外乱に強い（温度・湿度）
吐出するダクト間のエアが均一○ ○◎ ○○ ○○ ◎ ◎○○○com

有機・酸系の成分を発生させないcom

冷媒ガスが漏れない
緑錆が発生しない

使いやすい

重要

○

○ ◎ ○ ○ ○ ○○

◎○

◎◎ ○

◎

競合製品比較

重点項目

attbabbaaabbccbcc

3.5 4○△□○□

度□：現在の製品△：競合Ａ社
×：競合Ｂ社
目標値
新技術・新構造重点保証項目（ボトルネック技術）
過去の重大クレーム項目

1/2

△○

△□

○ ◎△□

○

△□

○

△□○
△□

○

○

△□

○

S3

□

○

C3 D3
C1 D1
C3 D2 S2
C3 D2 S2S5□○○◎○

D3C3C3 D4C3 D5△□○△□△□○△□○

Bottleneck ⇒ the Footprint is too Large!
⇒ Developing Target: Reduce the Footprint to ½att○：新製品の目標

目標設定

○ ○ ◎

3com a C7b
D1 S1bbb
D1 S1
att abS3bS3
com a C1 D12bD3

軽微な異常で止まらない

省フットプリント設置の際、工具が不要
配管の接続が容易である
ダクトの接続が容易
配線の接続が容易
風量の調整が容易
冷却水配管が無い装置
用力に純水を使わない

レ
競合製品比較
ベ○：新製品の目標 ル
セ □：現在の製品
ア△：競合Ａ社
重ク 要 ルプ
×：競合Ｂ社レ 望 ス項要項 ポ目ム 目 イ度ントb C6 D7
b C5 D8流量の制御精度が高い
あるチャンネル流量が、他チャンネルの流量変化の影響を受けない温度制御ができる

信頼性

品
質の性
質

流量調整可能範囲が広い

制御ができる（基本性能）

ﾕｰｽ制御ス補正)

耐震性)

耐久性

(加湿能力

(加温能力

1(熱交換器効率2(分布・流れ方ダク
ト径

1(

流量制御ができるル

風速

品質企画

3ッ

3次要求

冷凍機
能力

2ー

2次要求

1ー１次要求ー圧力・
風量

送風機のコン
トロ

2ー

送風機
能力

1△□○

S7△□○△□○○○◎

Outline of This Project
TRIZ Fully Follow Up
Theme determined

Essential issuesFunction analysis(Extractthe root cause)

Cause/result analysis
Extract root cause

Engineering contradiction
defining

Creation ofideas using
TRIZ

Creation of ideas using
invention principles

Ultimate MIR considering

Creation of ideas using
evolutionary patterns

Creation of ideas using
Knowledge DB and SFR

Idea associations and growth /BS
Idea classification/sort-out

Ideas utilized(Select and connect)

Idea combining in sub-system
Main system concept

System :Absolute evaluation

Final system concept: absolute evaluation

Selecting product concept

ARIZ

Outline of This Project
TRIZ: Functional ModelOutline of This Project
TRIZ: Cause and Result Analysis

Outline of This Project
Definition of Engineering Contradiction and Its Resolution
Root cause 1

Engineering contradiction matrix

Due to hardness of the pipe, the refrigerator size becomes larger.
Improving characteristics
Cope with engineering contradiction
Durable with high pressure.
EC-1

Refrigerant

Worsening characteristics

Use of hard pipe

Large R

Durable withhigh pressure

・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・

Hard pipe
Making “Larger”

Curvature R
Invention principles

Durable with high pressure
EC-2

10. Preliminary action

35. Parameter changes

40. Composite materials

34. Discharge and recovering

Refrigerant

Soft pipe
Curvature R
Making “Larger”

Outline of This Project
Session Scene

Outline of This Project
Examples of Ideas

One Day…

A person in chargeof corporation A
offered an inquiry
to Shinwa that is…

tieak?
mnouisonye
Can in dim
flahAccomplishments of This Project
External View of the Final ProductFootprint: ½!

2700

135 0Old TypeNew Type: SmallAccomplishments of This Project
Incidental Effects with Compactness
Power Consumption to2/3

Assembling Time: 15 % CutOld

NewWork Line Curtailed

Accomplishments of This Project
Incidental Effects of This Project

What You’ve
Learned with QFD:
Do it the Way
Customers WouldWant.

What You’ve
Learned with TRIZ:
Gain Effective Waysto Find Out Ideas.

Attendees’ Voice• An approach that converts customers’ requirements toparameters is the most useful.
• Upon a development, I realized two important things: first,clarify the goal (or objective) and second, solve the problem.
• I used to be satisfied creating only one idea before this project.
Now I try to create many ideas.
• I noticed as an engineer that I’d be able to expand mycapabilities by being accustomed to investigating useful
information such as Patent and knowledge using Goldfire.
• In case of problem solving concerning a discrepancy report(DR), I became able to create ideas with an aspect of TRIZ.

Future Plans
Two projects now are being developed using TRIZ in
the field of solenoid valve and motor valve.

High flow rate andhigh pressure
resistance areaccomplished.

Dimensions
would belarger incontrast.

Controlaccuracy isimproved.

The durability
would worsen incontrast.

Thanks to:• IDEA Inc.
Mamoru Zenko (President)
Hajime Kasai (QFD)
Masahiro Kuwahara (TRIZ)• All the Customers who Assign Us Challenging Issues.

Thank You for Your Attention.

Shinwa Controls Co.,LTD.