The Sixth Japan TRIZ Symposium 2010

TRIZ for Managers- Approach and Management using a Scientific Methods -Scientific methods (QFD, TRIZ,
Taguchi method, etc.) aretools for gaining, operation itself
and management itself!

2010. 9. 10

MOST, LLC
President

Kazuya Yamaguchi
Translated by Yoshihisa Konishi

Company Profile

About MOST, LLC
A group where retired employees of Panasonic and PanasonicCommunications Co., Ltd., who had mastered scientific methods(general-purpose techniques such as QFD, TRIZ, Taguchi method,
multivariate analysis, sales analysis, etc.) and were active at thecompany-wide work restructuring, have gathered together.
The name MOST was denominated with the following meaning:
You can get the MOST performanceby MOST ( Management Of Scientific Tool)
with MOST (MOST, LLC) .

MOST, LLC
1-19-11 Tobitake, Umimachi, Kasuyagun, Fukuoka
President: Kazuya Yamaguchi
E-mail:ygky.yamaguchi@kph.biglobe.ne.jp
TEL, FAX 092-932-9701

Biography of Kazuya Yamaguchi, President of MOST, LLC
1970.3

Graduated Communication Engineering Dept.,
School of Engineering, Kyushu University

1970.4

Joined Kyushu Matsushita Electric Industrial Co., Ltd• engaged in product development
served as technical section chief and manager• engaged in company-wide work reconstruction

Kyushu Matsushita Electric Industrial Co., Ltd
General Manager, Development Process Innovation Department
Panasonic Communications Co., Ltd.
Deputy General Manager, Management Quality Promotion Department(Japan Quality Award, development process innovation, quality innovation,
back-office section innovation, factory innovation), (2007.8.31 age-limit retirement)
Currently President of MOST, LLC (Established 2007. 9. 3)

Part time lecturer at Ritsumeikan University Postgraduate school (Quality Management)
Part time lecturer at Yamaguchi University (Leading edge in Development Process ）Part time lecturer at Kyusyu University (Management Quality Innovation)

Lecture Contents
I. The figure which a company activity aims at
1) The present conditions in development of products andthings, and the direction that we should aim at2) Relation between JQA(Japan Quality Award) thought
and application of scientific technique＊

II. Trans-Disciplinary Fundamental Technologies
1) What is needed to accomplish the mission of company activity2) What is QFD(Quality Function Deployment)!
3) What is TRIZ!
4) What is Quality Engineering (Taguchi Method)!

III. Summary
1) Creative problem solving process and scientific methods
2) Difference between scientific method utilization andcommon management!
3) What is TRIZ for managers!

I. The figure which a company activity aims at
1) The present conditions in development of products and things,
and the direction that we should aim at2) Relation between JQA(Japan Quality Award) thought
and application of scientific technique1-1) The present conditions indevelopment of products and things
Inefficient activity of own way
No management
Nonscientific contempt

A way of thinking to assume that
we are good at the level that we had(plan, quality, cost, delivery date, function)
Waste of money,
Waste of time,
Lose competitive advantage

We lose the trustof customers
Tough management
situation1-2) Direction that we should aim at”Approach and Management”
With rational scientific technical method
With future prediction and development of products

Good, early and cheaply

We have to realize necessarily, logicallyand scientifically
Products which are superior to other companies
Products development of good cost performance
Lighter, more compact facilities
1/10 facility development

We need a management
who can say thisHow will QCD be improved
when we use scientific technical methods?
Conventional development
technique management

We think to have fully drawn
abilities of engineers

1. Left to individuals
2. Management is difficult We can show only power of 30%
3. Without using the brain• Scientific technical method
utilizing management
We can show power of 130%
1. Tool is good
2. Technical argument
3. Argument by many

We can draw abilities ofengineers to the maximum

Management means to draw
abilities of engineers to the maximum

Increasing sales and profit
by strengthening
product competitivenessAssessment standard of JQA(Japan Quality Award)
1. Direction to aim at
JQA POV:
Customer/Competition/Reform

MB Award in US
President Regan

Result: Excellent achievement
2. Basic idea (The common sense of values that an organization
should have)1) Basic thought (4 elements)
Create and provide customer value(1) A customer-oriented The formation and display of the so
far few “original ability” that theway of thinking
other organization does not have(4) Harmony with society(2) Original ability(3) Employee serious
consideration
Contribution to society
Harmony with social value

Provide places and environment for
employees to exercise their autonomy
and creativity2) Decision-making by value premise
Value premise management from “ideal world” and “desirability”
Disapprove of fact premise management

Scientific method
Explore the ideal world
to a great deal

We will utilize QFD
and clarify an aim
Realizable with
QFD, TRIZ and
Taguchi method
Managers have toregard these methods
as management tools

Thought is sameas TRIZ and
Taguchi method

II. Trans-Disciplinary
Fundamental Technologies“thinking from the standpoint of a manager”

1. Necessity to fulfill mission of company activity
2. What is QFD(Quality Function Deployment)!

3. What is TRIZ!
4. What is Taguchi Method!

1. What are company activities and manager’s tasks
Steps for product creation at companies
Product creation = Requested quality elaborating activity = Intellectual creation activity

1. Marketing
Product plan

Surveying the market and decide
what kind of product to make

In what parts structure
2. Research and Development
to create the product
In what specification
3. Product development and design to create the product4. Fabricating method development In what facility / condition
to create the product
Factory
5. Sales (Market)
Service

Are the customers satisfied?

Producing excellent achievements and results …
responsibility of the manager also1-2) What to study! What to make study!
Essentials for products/things creation
Traditional approach
1. Expertise andtraditional quality
control techniques only

ceramic technology, electronics,
information engineering,
communication engineering,mechanical engineering, appliedchemistry, physics, aeronauticalengineering, electric engineering, etc.
7 tools for QC, TQM, FMEA, FTA, etc.

All-purpose technologies
where momentum gathered for
activities after 1990

Supports intellectual creativity andproblem solving is easily achievable

To be Added to the traditional:

The most important processes are
QFD, TRIZ and Taguchi method(world’s highest all-purpose
technologies)

2. Development process technology
Managers need paradigm
shifts to management

Besides, combined use of IT, etc.
is also required1-3) Product creation oriented
Company activity (production cycle) and Development process technology

Company activity

Effective(production cycle)

Development process technology

Marketing….. QFD

R&D..… QFD, TRIZ

Product development..… TRIZ, Taguchi Method

Fabricating method development ..… TRIZ, Taguchi Method
Production..… Taguchi Method

Verification….. Taguchi Method

Sales….. QFD

After-the-sales service….. QFD
Quality Engineering = Taguchi Method
in JapanoverseesII. Trans-Disciplinary
Fundamental Technologies
1. Necessity to fulfill mission of company activity
2. What is QFD(Quality Function Deployment)!

3. What is TRIZ!
4. What is Taguchi Method!

2-1) What is QFD?
(Quality Function Deployment)
The task of business management or manager begins
with accurately understanding the customer’s request

Method to accurately understand the customer’s request
The best way to create salable products
at various discussions including Product planning stage
reflecting matters (quality) requested by customers in
product creation
Goal clarification
Task clarification
Action item clarification

You may probably think thatsuch things are naturally
performed …

… but, actually, they aren’t
performed in most cases2-2) What is QFD?
(Quality Function Deployment)

A very simple binary sheet(1) How does thecustomer like?

2

Qualitycharacteristics(5) How should thespecification be tosatisfy the customer?

Design quality

4

Planned quality

53

Important degree

Requiredquality

Customerrequest1(2) What should beconsidered technically forthe customer request?
(3), (4)What kind ofcharacterization
will make thecustomer happy?

Important!
Don’t assess thefeasibility here

What is QFD? (Summary)• A method for clarifying what technical realization
would ensure the qualities that the customers request
and make them happy complying with their requests• A method that clarifies the design quality (objective)
thereafter
FeatureEnables investigation
without leaks

The best way to create salable products
reflecting the matters (quality) requested by customers in
product creation at various considerations including the
product planning stage

Concrete grounds for realization ofFirst, there is QFD
in any operation(including R&D)

technical problems is

in TRIZ!

II. Trans-Disciplinary
Fundamental Technologies
1. Necessity to fulfill mission of company activity
2. What is QFD(Quality Function Deployment)!

3. What is TRIZ!
4. What is Taguchi Method!

3-1) A method that supports thinking to enableeasy creation of only-one number-one products

What isＴＲＩＺ?

TRIZ / TIPS: (Russian) Теория Решения
Изобретательских

Задач

(English) Theory of Inventive Problem Solving

Enables structure
determination of a perfectsystem that is good in QCD
The basic of R&D

3-2) What is TRIZ?
• A tool that supports to easily generate all the ideas forsolving difficult technical problems by thinking based on
the human thought pattern at the research / development/ design stages

A tool that supports

creativity

1) Investigated and analyzed 2.5M past patents,• Patents are the thinking agglomerateof resourceful persons of all mankind

2) Systemized patents, and• Easily to utilize• Gives hints• Enables logical thinking

3) Created a tool that supports solving difficult
technical problems3-3) How is TRIZ thought pattern!
2.5M patent analysis systematized cases

Hints available 99%

TRIZ standardizes on essential analogies using excellent problem
solving case of the past in other fields as hints even for things thatseem to be the first case in one’s field, etc. and at the same timeon pursuing to make the maximum use of ideality and resources(1) Is the current technical problem an
unprecedented attempt for mankind?
Should be NO(2) Don’t you think that there is a solution case of
the past in another field that would give you a hint?
Should be YES(3) Are the existing resources utilized ideally?
Should be NO3-4) TRIZ is amazing. Why?
TRIZ

A way ofconventional work
• Nonscientificcontempt• Inefficient activityof own way• Whack-a-mole
R&D activities
after one’s own
style• Solutions within
the range which
one can think of orrecognize

This is the ultimate level ofknowledge management
1. There are all thought patterns of the human in
2,500,000 patents
Person acquiring USA patents is world top-level humanbeing

2. It is arranged wellPrinciples, Effects, Prediction

3. Thought aiming at is good
The philosophies of “pursuit of ideality”, “maximum
use of resources” and “contradiction resolution” areexplored to a great deal3-5) TRIZ structure (3 main pillars)
3

generate allideas for solving

Effects2

important

Prediction

1
Problem Definition

QFD

Engineering
Contradiction

Principleｓ

1

Engineering Contradiction Solving Matrix
39 Worsening
Parameters

39 Improving
Parameters

Area

LengthZ35, 01Pressure

Force

Area

LengthPressureorder

14, 16Force

Up to 4 Inventive Principle numbers used to solve
engineering contradictions are listed according to how
frequently they were used in the 2.5M patents

39 Engineering Contradiction Parameters
The same parameters are on the vertical and horizontal axes
21. Power
1. Weight of moving object
22. Loss of Energy
Parameters are
2. Weight of stationary object
23. Loss of substancedescribed in
3. Length of moving object
24. Loss of Information
very versatile
4. Length of stationary object
25. Loss of Timeterms
5. Area of moving object
26. Quantity of substance
6. Area of stationary object
27. Reliability
7. Volume of moving object
8. Volume of stationary object
28. Measurement accuracy
9. Speed
29. Manufacturing precision
10. Force (Intensity)
30. Object-affected harmful factors
11. Stress or pressure
31. Object-generated harmful factors
12. Shape
13. Stability of the object's composition 32. Ease of manufacture
33. Ease of operation
14. Strength
15. Duration of action of moving object
34. Ease of repair
16. Duration of action by stationary object 35. Adaptability or versatility
17. Temperature
36. Device complexity
18. Illumination intensity
37. Difficulty of detecting and measuring
19. Use of energy by moving object
38. Extent of automation

20. Use of energy by stationary object

39. Productivity

List of 40 Inventive Principles
Principles numbers are listed at the intersection of the matrix
Principle
numbers
obtainedfrom theLength vs.
Pressurecontradiction

35, 01
14, 16

1. Segmentation
21. Rushing Through2. Extraction
22. Convert Harm into Benefit
3. Local Quality
23. Feedback
4. Asymmetry
24. Mediator
5. Consolidation
25. Self-service
6. Universality
26. Copying
7. Nesting
27. Dispose
8. Counterweight
28. Replacement of Mechanical System
9. Prior Counteraction
29. Pneumatic or Hydraulic
10. Prior Action
30. Flexible Membranes or Thin Films
11. Cushion in Advance
31. Porous Material
12. Equipotentiality
32. Changing the Color
13. Do it in Reverse
33. Homogeneity
14. Spheroidality
34. Rejecting and Regenerating Parts
15. Dynamics
35. Transformation of Properties
16. Partial or Excessive Action
36. Phase Transition
17. Transition into a New Dimension 37. Thermal Expansion
18. Mechanical Vibration
38. Accelerated Oxidation
19. Periodic Action
39. Inert Environment
20. Continuity of Useful Action
40. Composite Materials

Prediction2(Law of Technical Evolution and Standard Solutions)

There are laws in• Technical evolution
and• Problem solving• Law of technical evolution
and• Standard solutions

Overview of “Standard Solutions” in ＴＲＩＺ
Total 127 items
A. Completing incomplete “Substance-Fields”
B. Detection and measurement problems
C. Eliminating harmful effects
1) Modification of an existing substance2) Modification of field
3) Introduction of a new substance4) Introduction of a new field
5) Introduction of a new substance and field
6) Transition to a subsystem
7) Transition to a super-system( 4 items )( 5 items )( 11 items )( 5 items )( 3 items )( 3 items )( 6 items )D. Improving insufficient or excess interactions
1) Modification of an existing substance2) Modification of field
3) Introduction of a new substance4) ) Introduction of a new field
5) Introduction of a new substance and field
6) Transition to a subsystem
7) Transition to a super-system

1 item12 items
37 items

65 items( 18 items )( 7 items )( 15 items )( 4 items )( 12 items )( 3 items )( 6 items )Field types … mechanical, optical, thermal, chemical, etc.
13 main types

3

Effects( Source: TechOptimizer )Engineering database of 5,888 scientific effects and applications
37 items to detect electromagnetic waves or lights:
Monitoring X-ray beam alignment
Screen for visualization of X-ray images
X-ray imaging array
Electret dosimeter
Optical information recording disc
Barkhausen effectPhotochromic effect (influence of intensity)
Optical memory based on photochromic materials
Holographic system
Hologram recording material
Roentgenoluminescence
Principal axes determination in anisotropic crystal
Fixing moving image frame
Producing image on liquid crystal display
Visualization of stress pattern
Resonant photodiffractive effect21 other items

3-6) Feature of ideas by TRIZ utilization
Consideration from all angles along TRIZ thought pattern(Idea generation)
Image ofidea consideration

Idea spreadthrough consideration in all directions• without overlooking and being right on target

Problem• ten to twenty times more ideas compared toconventional ratio

Idea convergence• Putting together as the best concept

Image ofclassificationGold

Silverutilizing all the enormous ideas
Bronzeconsidering the QCD quality and possibility3-7) Extract of TRIZ
1. Underlying thought of ＴＲＩＺ (Goal)
We can image the ”ideal solution”• Thorough pursuit of ideal and evolution ofsystem• Maximum use of free resources• Minimum introduction of paid resources
Result: Seeking an ideal solution,
the quality also improves naturally… same as with Taguchi method

2. Full with hints for solving to ideal solution3-8) Utilize TRIZ, and develop
tactics/strategies for short to long term
Even strategies can be developedby idea generation keeping the ideal solution in mind
Ideal characteristics(Ideal situation)

Long
term
Futureconcept
MiddleNext generation
term
product

Tactics
Short
term

New
product

Strategies

Existing product

Generation

Advance patent application3-9) TRIZ (Summary)Management• Management that supports thinking to enableeasy creation of only-one number-one products• Supreme knowledge managementTool• A tool that supports to easily generate all the ideas
for solving difficult technical problems by thinking
based on the human thought pattern at the research/ development / design stages

Product• Within crushingly short time,enables concept (system structure) of a perfectproduct that• excels in ideality and goes ahead of the times

Taguchi method

3-10) How to use TRIZ actually?
1. Define voice of customer and the goal we want to create
Product plan … what should be possible technically?

Product concept (Goal)

Research and development … what should be possible technically?
Clarification of goals (The higher the goal, the better)
… QFD
2.

• Embodiment on the desk

Research and Development …
What kind of thing can be technically done?
Design … We want to largely lower component cost(brain only)• Foresee the future(from tactics to strategies)

ＴＲＩＺ
Schema clarification on the desk (with the brain only)

Concrete product concept(Product creation that makes positive impression on customers)

Enables structure determination of a perfect systemthat is good in QCD

Products creation
tolerant of error
Taguchi method conditions

II. Trans-Disciplinary
Fundamental Technologies
1. Necessity to fulfill mission of company activity
2. What is QFD(Quality Function Deployment)!
3. What is TRIZ!

4. What is Taguchi Method!
1) What is Taguchi Method?

2) Basics of Taguchi method
3) Summary of Taguchi method

4) Application to software5) Taguchi method case (31-legged race)6) Approach and management for people who don’t know Taguchi method

1-1) What is Taguchi method?

• TRIZ can be strongly promoted
because there is Taguchi method• Taguchi method is vital forstrongly promoting TRIZ

• The world’s best comfort technical method
to secure quality in research / development / design stage
1.

The founder Dr. Genichi Taguchi (1924- )2. Action start from about 1950
3. 1960 Received Deming Prize

He is called the man who revivified the U.S.A.

4. In the middle of 1980’s, he applied Taguchi method to stagnant American auto industry andbrought it back

Demonstrated that Taguchi method is practical
6. 1988 Inducted into United States Hall of Fame of International Science & Technology (Da Vinci,
Newton the sixth living person)
7. 1993 “The Taguchi Method Forum” established in Japan (Changed to Quality Engineering
Society)
8. 1994 Inducted into United States Hall of Automation(Soichiro Honda, Eiji Toyoda, Genichi Taguchi, Yutaka Katayama, Jiro Yanase, Shoichiro Toyoda)

9. 1997 Dr. Taguchi entered American car palace (The third Japanese. Six present)2) Basics of Taguchi method (1)A general idea ofcontrol engineering

We have to control characteristic ofcontrol factors to minimize influence ofnoise factors

Input

systemOutputoutputoutputNoise factor

input

Small variations
Large output

input

2) Basics of Taguchi method (2)Orthogonal
experiment

1
2
3
4
5
6
7
8
9

control factor
Ａ Ｂ Ｃ Ｄ1 1 1 11 2 2 2
1 3 3 32 1 2 32 2 3 12 3 1 23 1 3 23 2 1 33 3 2 1

Factoreffect chart1) Combined experimentwith orthogonal arrays2) Creating the factor
effect chart3) Estimate of the
optimum by the factor
effect chart

SN ratio

１ ２ ３

Ａ

１ ２ ３ １ ２ ３ １ ２ ３

Ｂ

Ｃ

Ｄ

Sensitivity

１ ２ ３

Ａ

１ ２ ３ １ ２ ３ １ ２ ３

Ｂ

Ｃ

Ｄ

Estimate of the optimum by the factor effect chart(1) In any case, Minimize variation
Enlarge S/N ratio … SN ratio = 10 log (m2/σ2)(2) Then, Match the mean
Adjust with sensitivity … Sensitivity = 10 log (m2)
We match the mean with the targeted value withhaving kept variation small
σ ＝標準偏差, ｍ＝平均値

2) Basics of Taguchi method (4)Confirmation experiment(Experiment at the level of predicted control factor)
1) Predicting the level of control factor from the factor effect chart(1) From SN ratio, set up level of control factors that lessens variations(2) From Sensitivity, set up level of control factors that matches the mean with the targeted value2) We perform an experiment for confirmation whether the target characteristics are
met under the limit condition of the variation (N1, N2) that took an error factor into accountIf basic design is a bad system, the limit of a system becomes clear(Teaches early that there is no use to carry on)
In this case, the decision for a fresh design

start enables lean development
If basic design is a good system,

Both area system of good quality with little variation is completedQ3) Summary of Taguchi method (1)Current quality field problems
barren money
Development / Design
Trouble in quality finish

Taguchi method is a tool thatmeets quality field problems
The best tool for a quality finish

Factory
Low yield ratio
Hard-core large variations
fresh start by lot rejection
Hard-core overtime workand holiday work

MarketDefective returned goods
from customers
There are many reworks

A tool that puts its first priority
to thoroughly suppress variation

A tool that prioritizes customer
viewpoint and puts its first priority
to thoroughly meet the change ofenvironmental condition in markets

C3) Summary of Taguchi method (2)Taguchi method is Dr. Taguchi’s heartfelt appeal!
A theory that arose from “Companies must be strong in cost”

A theory suitable to fulfill the mission of the company
Company has to make good products early and cheaply

A theory for creating
little variation (good quality) products
from much variation (cheap) parts“

A wise remarkof Dr. Taguchi“Quality first” crushes the company

D3) Summary of Taguchi method (3)Conventional
experiment

As a result of demanding
quality goods

Run into theDevil’s Cycle

Suddenly• We are going to make the most suitable thing• We are going to make a thing of good quality

Experiment of Taguchi method
Two phases of designs

Defective products
are rather made• Minimize variation (first phase)• We find the optimum (second phase)

A made thing is defective product

Conventional type:
Development type to preventfrom repeating failures
Development type to solve
the problem beforehandwith Taguchi method

No never-ending cycle
Straight to the result

We make quality goods
with a confirmation experiment

Sure approach4. Application to software
Effect of
Utilizing ”orthogonal array,” Introduction• excellent time efficiency and• increase in bug discovery rate
were tried

I hope that you utilize it hereafter
for “bug elimination on the market”4-1) Why are combination tests difficult?
Are combination tests done?
(1) Combination condition number is enormous
For 100% combination for 3 factors▲～×

Hundreds of thousands to several million module level cases

Number of cases realistically testable is less than 1,000(2) Difficult to separate accurately
because of complicated conditions

××(3) Number of tests further goes up
by state transitions through combined conditions
In traditional testing,no remedy but
evidently to takesecond best

Inescapably,
introduction of
combination bugs

4-2） What is an Orthogonal array?
• Usually uses the 2 Level System ( 2, 4, 8, 16, 32, 64, 128, 256, … )[ Column] Corresponds to# of levels # of levels # of levels # of levels # of levels # of levels # of levels
4
4
4
4
2
2
2

function for software
verification[ Row] Corresponds toverification number forsoftware verification
Combination of columns 1 and 2
Levels 1 to 4 for column 1
Levels 1 to 4 also for column 2
Each of the combinations of each levelof columns 1 and 2 appears once:
1-1, 2-3, 3-4, etc.

row 1
row 2
row 3
row 4
row 5
row 6
row 7
row 8
row 9
row 10row 11
row 12
row 13row 14row 15row 16column 1 column 2 column 3 column 4 column 5 column 6 column 7
1
1
1
1
1
1
1
1
2
2
2
1
2
2
1
3
3
3
2
1
2
1
4
4
4
2
2
1
2
1
2
4
2
1
2
2
2
1
3
2
2
1
2
3
4
2
1
1
1
2
4
3
1
1
2
2
3
1
3
2
2
2
1
3
2
4
1
2
1
2
3
3
1
4
1
2
2
3
4
2
3
1
1
1
4
1
4
3
1
2
2
4
2
3
4
1
1
1
4
3
2
1
2
2
1
4
4
1
2
2
1
2

Combination of columns 4 and 5
Levels 1 to 4 for column 4
Levels 1 to 2 for column 5
Each of the combinations of each levelof columns 4 and 5 appears twice:
1-1, 2-1, 3-2, etc.

Combination of columns 6 and 7
Levels 1 to 2 for column 6
Levels 1 to 2 also for column 5
Each of the combinations of each levelof Columns 6 and 7 appears four times:
1-1, 1-2, 2-1 and 2-2

4-3) Characteristics of Orthogonal array1) All the levels described by 1 factor ( 1 function ) can be checked( 100% cover rate )2) All the combinations of 2 factors ( 2 functions ) can be checked( The greatest characteristic …100% cover rate )3) Combinations of 3 factors (3 functions ) can be checkedwith about 60% to 80% cover rate, unintentionally4) Combinations of 4 factors (4 functions ) can be checkedwith about 30% to 50% cover rate, unintentionally5) near to 100% cover rate possible as relation combinations( assuming inputs ofevery 5 years for years and every 3 days for days
because the numbers of them are large )4-4) Embedded software test method using orthogonal array
MOSTEST method ( Method using Orthogonal array for Software Evaluation Testing )Feature / EffectSome creative thinking
in the orthogonal array

Realizes 100% cover rate ( 2 factor combination test )using orthogonal arrays based on Taguchi methodwith excellent time efficiency and accuracy

Secure discovery ofstate transition paths

Overview of MOST’s software verification tool
1. Enter the relationships between condition
factors and configuration factors
2. Enter simple factors and their levels

1. Enter state transition relations
2. Clarifies needed tests (automatically)
3. Enter factors and their levels

Automatically finds the optimal orthogonal array from thearranged 1909 kinds ( variants of L256, L128, L64, L32, L16 ) , and automaticallygenerates an orthogonal array ( describing factors and levels )for bug verification• 2 level system L16 max 16 factors, L8 max 25 factors, L4 max 32 factors, L2 levels max 254• Simultaneous processing possible for 4 kinds of factor ( One of L16, L8, L4 or L2 )• Level of configuration factors is one of L16, L8, L4 or L2(level # of condition factor 1 * level # of condition factor 2 * level # of condition factor 3 * level # of condition factor 4 * level # of configuration factor <= 256 )225-1) Taguchi method practical case introduction
Shoudai-Daini Municipal Elementary School,
Yanagawa City, Fukuoka Prefecture( Unwittingly practicing Taguchi method truly )National winner in
31-legged race!
Question“What kind of derby is the 31-legged race?”
Answers of many
“One to run keeping steps with each other???”What kind of approach did they take?
Taguchi method vision
to all day-to-day affairs!

1. What is the basic function?

“31-legged race” is a derby running“the same number of steps” “at the same speed” “keeping in line”
2. How was the goal set?

All ran 50 meters one at a time

Quality control method
Number of steps: central value of all was 34 steps
Speed: time level of national winner was 9.2 seconds

3. What kind of practice was taken?

All purchased a stopwatch

Nothing was created

Practiced to count 34 in 9.2 seconds
4. How was the variation?

Wonder: Wow, variation of 0.03 seconds!

Time at national championship Less than Olympian in the 100m
Game 1: 9.29s Game 2: 9.26s Semifinal: 9.28s Final: 9.28s

6) Approaches and management for people
who don’t know Taguchi method
The approach and management for research / development / designthat is firmly believed to be best and performed everyday by almost all
the people who do not use Taguchi method:
1) design it2) make a trial product3) detect malfunction4) study a cause of malfunction
Recurrence prevention5) remove the cause of malfunction type development6) change the design to adjust to the standard
6）raise the completeness by repeating the process 1) - 6) many times7） Whenever malfunction happens in the market, より厳しい
test method is added and a severer evaluation standard is set

Let’s immediately stop with such an inefficientapproach and management that lacks logic!
New technical fielddevelopment

proactive typedevelopment

Taguchi method

III-1) Summary
Creative problem solving process
and scientific methods
To use TRIZ well, “QFD”and“Taguchi method” must be used well changing the time
The relation among the 3 major methods is that none of them is superior to the others
There are only time lags in their activities
Defines system requirement function and problem
QFD areaavailability

Taguchi method area
realizes the best system
TRIZ area

QFD

securessystem quality

Research Development Design Production time axis

III-2) Summary
Difference between scientific method utilizationand common management!
Outcome (profit)
Scientific method applied management
Scientific methods are not magic tools!
They are effective like magic, but
it is to go over consistently,

Bring result of QFD review! ( Review closely! )Utilize scientific methods! ( Play full out! )Utilize scientific methods! ( Give it your all! )without omission, robustly,
Show ideas generated with TRIZ!
and at world-class level and to( Combine the wisdom of all! )make to make to do so!
Bring data of Taguchi method review!
( Reduce defects radically! )Common management
What and how to do?
Trial and error by the manager and also
by the person in charge
Consequently, difficulty yielding results0

Review substantially!
Give it your all!
Play full out!
Combine the wisdom of all!
Reduce defects radically!

Input energy ( man, things, money )III-3) Summary
What is TRIZ for managers!
1. Clarification of goals (The higher the goal, the better)

Product concept (goal)… QFD

2. Research and Development … What kind of thing can be technically done?
Design … We want to largely lower component cost

• Embodiment on the desk

TRIZ

(brain only)

Schema clarification on the desk (with the brain only)• Foresee the future(Product creation that makes positive impression on customers)

Enables structure determination of a perfect systemthat is good in QCD

3.

(from tactics to strategies)

Concrete product concept* System configuration ideas
to ensure the quality requested by the customers anddetermine concrete condition setting ( set value ) at product creation* pinpoint the true factor of large variations and determine the improve conditions* Determine the conditions so that quality can be ensured even with cheap materials* Determine operating condition of equipment in the factory

Taguchi method

Products creation
tolerant of error
conditions

Thank you for your attention!
I hope that you will further improve your managementby acquiring or making to acquire good methods andperforming good management ( utilization of scientific methods )