Design risk prevention by the SN Matrix
and TRIZ process～The functional approach for connecting the methods and 7 solutions～

September 11, 2014
Hiroyuki Tsuchiya、Shibuya Tetsunori、Takashi Ogata
ECM Promotion Department
Monozukuri Solution Division
Olympus Corporation

Presentation of Today
1. About Olympus
2. Promotion of scientific methods in Olympus
3. Request for risk analysis from engineers
4. New approach for risk analysis
5. To determine target follow purpose
6. To extract factors
7. To use new SN matrix for risk analysis
8. To extract risk
9. Using new SN matrix at all solution
10. Summary2

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1. About Olympus
Medical Business3
Established : October 12, 1919
Head office : Shinjuku-ku, Tokyo, Japan
Capital : ¥124,520 million (As of March 31, 2014)
Consolidated net sales : ¥713,286 million(Fiscal Year Ended March 2014)
Consolidated headcount : 30,702 (As of March 31, 2014)‫‏‬Imaging Business

Scientific Solutions Business

EVIS EUS Endoscopic Ultrasound Center
EU-ME2 PREMIER PLUS

E-M10

STYLUS
SP-100EE(Eagle’s Eye)

Surgical Energy Device THUNDERBEATSTYLUSSH-1
Disposable guide wire
「VisiGlide 2TM」
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UIS2 objective lensseriesLaser scanningmicroscope fororganism「FLUOVIEW1200」

Imaging software
Ultrasonic thickness for Biologicalmicroscope
gauge「cellSens®」「27MG」

2. Promotion of scientific methods in Olympus (1)4Providing 7 solutions for the purpose.
2010

2009

Solution for2012 ～Fuzzy Frontend

QFD

QFD
QFD

Short time

Short time

TMTM

Functionality
assessment

Limited purpose
Problem setting type

TRIZLong timeLong time

Original QFD

Short time

Parameter design

TRIZTRIZ

One loop TRIZLong time

Typical Use ofMethods

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Some loops or PAT TRIZ

※One method to use
in some cases

Using various types of methods according to the problem
90 min Basic Training, applied to the theme

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Fast Cause Analysis
Making Strong Patent
Cost Reduction

Only
Creation of Idea

TM

Setting Theme

Evaluation & Experiment
Risk Prevention
Providing optimal solutions
to the problem

2. Promotion of scientific methods in Olympus (2)5The functions of system can connect 7 solutions and methods.
Process is connected by the concept of function wherever you open the drawer
TechnologyDevelopment

Core Method Search

Product Design

Fuzzy Frontend

QFD TRIZQFD Fish bone chart
Fish bone chart

Preparation
for production

Production

Case of project
Setting Theme
Fast Cause Analysis

TRIZ TM

Making Strong Patent

QFD TRIZ
TRIZ TM
TRIZ TM DOE

QFD TRIZ TM

Cost Reduction
Evaluation & Experiment

Risk Prevention※ TRIZ includes Functional approach and Root cause analysis.
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2. Promotion of scientific methods in Olympus (3)6What is “risk ” in risk prevention solution atOlympus？
For regarding "risk" handled here, it is to predict safety
and quality of products and processes, and to avoid it
when the engineers design products and processes.
To be analyze efficiently by adding scientific approachto general FMEA.

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3. Request for risk analysis from engineers (1)7

Our engineers opinions for risk analysis are asfollows.
Unexpected failures have occurred , even if
veteran members analyzes risk.
⇒ We have checked the drawing over time withveteran members. Mistakes occur at inexperienced
new design particularly.
Risk analysis is inefficient.
⇒ Risk analysis need long time, because of to needanalysis on component level in entire system.
But want to exclude big risk even for short time.

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3. Request for risk analysis from engineers(2)8Reason why these opinions happen?
Why not enough with veteran?
・Veteran has ”Belief” that rely on pastexperience. It is not enough for
inexperienced new design.
・Factors at movement and flow can notfind at the drawing.

Why need long time?
・Without sufficient understandingof the purpose, begin to analysis.
・To use time uniformly for eachfactors, with or without effect.

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How should we
do to reduce time
and to raise thecompleteness forrisk analysis?

4. New approach for risk analysis

9Comparison of general FMEA and our approach.
PurposeOur Approach

General Approach

１ To determine target

Focusing the target by fish bone
chart and function diagram follow
the purpose.

Choosing target with actual
experience and actual
knowledge.

２ To extract factors

Extracting factors with multifaceted from the point of view oftime and space by SN matrix.

３ To extract risk

Extracting risk by TRIZ effects inthe broad view and generalized
functions.

Extracting risk with experienceand stored data by reliability
block diagram and thedrawing ,failure mode table.

４ To evaluate risk

Evaluating each risk by SN matrix,
follow the purpose ,competitor,
and user needs.

Evaluating risk with general
items.

５ To avoid risk

Clarifying resolution parts withfunction, for to use TM and TRIZ.

Use Brainstorming or othergeneral method.

( Completeness
improvement 1 )( Completeness
improvement 2 )92014/8/6

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5. To determine target follow the purpose (1)10Determining target by fish bone chart.
DFM
E
A

PurposeModification
To ensure Focusing to the large
the safety energy part accessed byhuman, and the part thatdesign changes.
To ensure Focusing to the main
the quality function of the product,and the part that designchanges.

New design
Focusing to the large
energy part accessedby human.
Focusing the mainfunction of the product.

For safety, to focus on part having an energy that human cantouch.
For quality, to focus on deviating the main function of the product.
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5. To determine target follow the purpose (2)11Determining target by fish bone chart.
Target of quality assurance
Spatial functional
approach

Focusing to the main function ofthe product, and the part thatdesign changes.

《Examples of projector》

Projection opticalsystem

Light switch

Control factor
LCD Shutter

Dichroic mirrorLens

Circuit ofimage signal

Circuit of
LCD shutterLensholderActuator oflens

Un control factor

Circuit ofactuator
Quality of safety

heat radiating
fins

Structuralpart

Light bulb

Cooling fan

Power forlight

Air vent
Adjuster
Housingsystem

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Power unit
Light unit

Circuit ofpower
Light shaping
lensTarget of thesafety
Focusing to the large
energy part accessedby human, and the partthat design changes.

6. To extract factors (1)12Analyzing functions by SN matrix. (function tree)
S+V+O

S+V+O

S+V+O

S+V+O

S+V+O

S+V+O

BOM*
Drawing（Still image）

Missed function at moving
mechanism.
SubjectLens

Spatial functional approach①Eliminating leakage with the spatial function approachthat is based on the BOM.
S+V+O

S+V+O
S+V+O

CCD

time

S+V+O
S+V+O

Process FlowEx.) moving lens＊BOM：Bill of material
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Time functional approach②Eliminating leakage with the time function approachthat include process flow.

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6. To extract factors (2)13①Eliminating leakage with the spatial function approachthat is based on the BOM.
Spatial functional approach

According to layer, fill in the table
only the function.

Layer

Projection optical system collect light tothe screen

1

BOMFunction（S+V+O）

11

Lens collect light12

Lens holder hold the lens

13

Lens actuator drive the lens14

Circuit of actuator sends an electrical signal
to the lens actuator
Light switch control the emitted light2
21

LCD shutter open(close) the emitted light22

Circuit of LCD shutter drive the LCD shutter

Attention to V of S+V+O.
《Examples of projector》
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ＳVＯ6. To extract factors (3)14②Eliminating leakage with the time function approachthat include process flow.
Time functional approach

Spatial functionalapproach

Process Flow
《Examples of projector》
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Timeflow

Function（S+V+O）
Light switch control the emitted light1
11

Circuit of LCD shutter drive the LCD shutter

12

LCD shutter open(close) the emitted light
Projection optical system collect light tothe screen

2

21

Circuit of actuator sends an electrical signal
to the lens actuator

22Lens actuator drive the lens

23

Lens holder hold the lens

24

Lens collect light

Cleary S+V+O.
ＳVＯ

Process flow of function.

According to process flow, fill thetable from time functionalapproach.

7. To use new SN matrix for risk analysis

15

Analyzing risk of each function by time and spatial analysis
and TRIZ.

Spatial functional approach
Time functional approach
Priorities follow
concept of QFD.
Function Layer

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Prior
ity

TRIZ Effects

Seeds

Needs

Extracts the possible riskfor each function, evaluate
risk by RPN.

Survey otherCustomer request
companies technology.

Risk ofFunction(S+V+O)

RPN

Competitor’sTechnologySO

DRPNLevelContents

Voice of Customer○Deterioration of thelens due to sunlight

33218・・・

Patent A

Want to use outdoor◎

V-oscillator circuit
distort the image

34224・・・

Patent B

Want to show indetail

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8. To extract risk (1)16Extracting risk by TRIZ Effects.
ＳＳVＯＳＳVVVＯ

Investigating problems at each function with expandfunction. （Use Goldfire*）

ＯCan refer problems of other fields by generalized
function of system.

Ｏ⇒New discoveries and awareness can be obtained.
By dispel the belief and experience,
it is no longer missing leakage of risk analysis.

Left products are using light.
By generalized function of system , it ispossible to refer to common problem.

＊Goldfire：Innovation support software
Invention Machine Corporation under IHS
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8. To extract risk (2)17Investigating the problem at each functions.（Use Goldfire*）
Want to find risk for"to collect light".

Investigating cause of “Can’tcollect light" by cause finderof Goldfire.

Found new risk !
“Influence from sunlight”

Cause finder of Goldfire

In vehicle headlights, risk of degradation, corruption from sunlight has. If
you do not know user want to use at outdoor, this risk will not to think.

⇒Add to SN matrix, of found risk.
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8. To extract risk (3)18Investigating the problem at each functions.（Use Goldfire*）
Want to find risk for"to collect light".

You can find cause of “Can’tcollect light”. Investigating
cause of “distort image" bycause finder of Goldfire.

Found new risk !
“Influence from Voltage
Cause finder of Goldfire
controlled oscillator circuit”
In printer, distortion of the image is generated by varying the reference
voltage of the voltage controlled oscillator circuit at the time of printing. By
generalized in function, it was possible to extract risk from the case ofother fields.

⇒Add to SN matrix, of found risk.

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No data copy / No data transfer permitted9. Using new SN matrix at all solution

19SN matrix for connecting 7 solutions.
Solution use same process with function and customer needs, competitor.
SearchTechnologyDevelopmentSNmatrix

Fuzzy Frontend

Product DesignSNmatrix

Fast Cause Analysis

Making Strong Patent
SNmatrix

Cost Reduction
SNmatrix

Evaluation & Experiment
SNmatrix

Always We can use TRIZ by
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Production

Setting Theme
SNmatrix

SNmatrix

Preparation
for production

SNmatrix

Risk Prevention

10. Summary

20① By determining the target according to the purpose, Risk
analysis has enabled more efficient and short-time.
② Seeds and Needs matrix (SN matrix) and TRIZ can be raisecompleteness for risk analysis.
③ By thinking of function, TRIZ has become easier to use at allsolution.
By using TRIZ, reducing time, reducing leakage and dispel thebelief, it had become possible to efficient analysis.
<Challenges for the future>
For process design, considering how to raise the completenessfor risk by "human error“.

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Special Thanks

21Thanks to Mr. Mamoru Zenko and Mr. Hajime Kasai of IDEA, INC.
They provided the chance of using scientific methods (QFD + TRIZ)
and support for our activities at OLYMPUS.

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Thank you for your attention