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IntroductionIntroductionToTo

TRIZTRIZJohn Vandenbemden

QAIMaster Six Sigma Black Beltwww.trainingforQuality.com

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SS DMADV – A Cyclical Process

Define

AnalyzeAnalyze

Verify

MeasureDesign

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AnalyzeGenerate, evaluate and select the best concept that meet the CTQs within budget and resource constraints

Generate, evaluate and select the best concept that meet the CTQs within budget and resource constraints

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The Benefit of DFSS Innovation

• The time advantage of innovation

TimeAdvantage

Companies using Continuous Improvement & Continuous Innovation

Competition using onlyContinuous Improvement

Impr

ovem

ents

/ V

alue

Time

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Develop Design Concepts

Left Brain

•Functionality (FMEA)••TRIZTRIZ•Trend Analysis•Statistical Analysis

Right Brain

•Brainstorming•Brain writing•Assumption Busting•How lucky are you?

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Idea Generation Techniques

• Modified Brainstorming• Brainwriting• Assumption Busting•• TRIZTRIZ

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TRIZTRIZProjects frequently reach a point where the analysis is completed and the team is at a point where it is unclear where they need to go for resolution. This applies not only to projects but to problem solving, root cause analysis, or even Six Sigma (upon completion of the analysis phase). The project team must be creative in order to determine what to do next. TRIZ minimizes the chance of unpredictable and unrepeatable results that are associated with brainstorming or brainwriting.

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TRIZTRIZ• TRIZ is based on the idea that many of

the underlying “root” problems that engineers face today contain elements that have already been solved (approximately 90%), often in a completely different industry, for a totally unrelated situation, that uses an entirely different technology.

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• The most important recognition is that “technical systems evolve”– Which evolves towards the

increase in ideality• By overcoming Contradictions

–Achieved primarily with the minimal introduction of resources

TRIZTRIZ

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T.R.I.Z. (Trez or trees)Theoria Resheneyva Isobretatelskehuh ZadachTheory of Inventive Problem Solving

– Developed after WWII (1946) by GenrichAtschuller (1926-1998), a Russian inventor and naval officer. He was sent to the Siberian Gulag camp by Stalin for thinking too much. He was released from prison after Stalin’s death.

– Based on a theory that there are universal principles of inventive and creativity.

– TRIZ is structured method that can be used to rapidly generate plausible concepts that solve problems in technical and non-technical domains.

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Altschuller / T.R.I.Z. • Started with 400,000 patients, today it

includes the study of more than 2.5 million patients.

• Altschuller discovery:– Each innovative patient solves a technical

problem, but across domains, there are common solutions. These solutions were boiled down to 40 principles.

– Inventive problems often carry with them inherent contradictions. (e.g. stronger, but heavier)

– Anyone can use this knowledge and methodology to solve problems.

– Resources are often idle during problem solving.

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TRIZ’s Inventive Principles1. Segmentation2. Extraction, taking out3. Local conditions, quality4. Asymmetry5. Combining, merging6. Universality7. Nesting8. Anti-weight9. Prior counter-action10. Prior action11. Cushion in advance12. Equipotentiality13. Inversion14. Spheroidality15. Dynamicity16. Partial-excessive action17. Shift to a new dimension18. Mechanical vibration19. Periodic Action20. Continuity of useful action

21. Rushing through skipping22. Convert harm into blessing23. Feedback24. Mediator25. Self-service26. Copying27. Disposable object, cheap28. Replacement of mech. system29. Use pneumatic or hydraulic30. Flexible film or thin membrane 31. Use porous material32. Change color33. Homogeneity34. Rejecting and regenerating parts35. Transformation of phys and chem.36. Phase transition37. Thermal expansion38. Use strong oxidizers39. Inert environment40. Composite materials

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TRIZ MethodUnderstand the problem as a

system

Understand the Understand the problem as a problem as a

systemsystem

Locate conflictsLocate Locate

conflictsconflicts

Identify Resources

Identify Identify ResourcesResources

Systematically explore solutionSystematically Systematically

explore solutionexplore solution

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TRIZ

Thus;

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The Three Premises of TRIZ• Ideality (ideal solution)• Resolve Contradictions• System Approach

TRIZ Approach/Tools• Innovation Situation Questionnaire (ISQ)• Problem formulator• Substance-Field Analysis (Su-Field)

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Why TRIZ ?• Simply stated, we need to create

innovative products and services to remain competitive !– We need to significantly improve the

engineers ability to quickly solve difficult and seemingly impossible engineering problems which often lead to next generation “innovative” products.

Creative Problem Solving!Creative Problem Solving!Creative Problem Solving!Provides a Dialectic Way of Thinking!Provides a Dialectic Way of Thinking!Provides a Dialectic Way of Thinking!

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The Innovation LeverThe Innovation Lever

TRIZKnowledge

InnovativeSolutions

IndustryKnowledge

CompanyKnowledge Your

Knowledge

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Example

• Generic problem solving, think in broad terms:– Principle #3 Local Conditions / Quality

– Airport with smoking areas– Yard light with a photocell– Pen with an eraser

• Combine several techniques and tools to enhance problem solving

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Altschuller Contradiction Matrix• The 40 Inventive Principles can be utilized to solve

problems but unfortunately, fixing one problem often results in creating another problem.Examples: – Companies buy other companies to grow and

strengthen themselves. This often results in a company disorganized and less stable.

– Coffee should be hot for enjoyable drinking but cool enough to prevent burning the drinker.

– Bandwidth increases (Good) but requires more power (bad)

– Training increases competence (Good) but requires employees to be away from their job responsibilities (bad).

• These contradictions can be resolved by applying the Contradiction Principles in a Contradiction Matrix.

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Altschuller Contradiction MatrixAs you can see from the examples on the previous slide there are two categories of contradictions.

1. Technical contradictions are based on classical engineering of “trade-offs.” The desired state can not be obtain because there is a barrier in the system.

2. Physical contradictions (Inherent) are situations in which one object or system contradicts the requirements of the other.

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Contradiction Principles1. Weight (of object in motion)2. Weight (of stationary object)3. Length (of object in motion)4. Length (of stationary object)5. Area (of object in motion)6. Area (of stationary object)7. Volume (of object in motion)8. Volume (of Stationary motion)9. Speed10. Force or Intensity11. Stress or Pressure12. Use of Energy (of object in motion13. Use of Energy (of stationary object)14. Duration of Action (of object of motion)15. Duration of Action (of stationary object)16. Temperature17. Illumination intensity18. Difficulty in monitoring or measuring19. Productivity20. Object generated harmful effects

21. Shape22. Stability23. Strength24. Power25. Losses of energy26. Losses of substance27. Losses of Information28. Losses of Time29. Quantity of Substance30. Reliability31. Measurement Accuracy32. Manufacturing Precision33. Harmful external effects34. Ease of manufacturing35. Ease of operation36. Ease of repair37. Adaptability or versatility38. Device complexity39. Extent of automation

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ContradictionsContradictions appear first as a gap between demands and supplies. They are overcome by break-through inventions. These inventions form the micro-steps of evolution in technical systems. Since the solutions are not known, creative problem solving is the method utilized to overcome contradictions.

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Contradiction Matrix

• Are a result of Altschuller’s patent research• The principles are technical characteristics• Can be applied throughout the Six Sigma

DMADV process whenever conflicts or contradictions arise.

• It is a large table that link pairs of the engineering principles (39 X 39 matrix).

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Contradiction MatrixWorsening Feature

Improving Feature

Weight of moving object 32, 21 12, 5 –

Weight of stationary object 32, 21 – 6,9, 23,31

Length of moving object 12, 5, 34 – 1, 5

Length of stationary object – 6,9, 23,31 1, 5

Weight of moving object

Weight of stationary

object

Length of moving object

Length of stationary

object

Inventive Principle that can be utilized to

identify a solution

Inventive Principle Inventive Principle that can be utilized to that can be utilized to

identify a solutionidentify a solution

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Contradiction Matrix

The core process is to drive a physical contradiction (using the matrix) and solve it with the Separation Principle. Once the physical contradiction is determined this solution technique is powerful enough to identify break-through (innovative) solutions.

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TRIZTRIZ works and is used by large as well as small organizations on several levels to solve real, practical everyday problems. TRIZ is utilized at companies such as Ford, Motorola, Proctor & Gamble, Eli Lilly, 3M, LG and …

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Summary

Innovative concepts are critical and a necessity to drive the optimization efforts to design new products or redesign exsisting processes or products.