Statistics for Innovation

Statistics for Innovation

Pasquale Erto Editor Statistics for Innovation Statistical Design of Continuous Product Innovation 123

Pasquale Erto Department of Aerospace Engineering University of Naples Federico II, Italy ISBN 978-88-470-0814-4 e-isbn 978-88-470-0815-1 DOI 10.1007/978-88-470-0815-1 Library of Congress Control Number: 2008939992 2009 Springer-Verlag Italia This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any otherway, and storage in databanks. Duplication of this publication or parts thereof is only permitted under the provisions of the Italian Copyright Law in its current version, and permission for use must always be obtained from Springer-Verlag. Violations are liable for prosecution under the Italian Copyright Law. Cover concept: Simona Colombo, Milano Cover picture: Riccardo Dalisi Typesetting: le-tex publishing services ohg, Leipzig, Germany Printing and binding: Grafiche Porpora, Segrate, Milano Printed on acid-free paper Springer-Verlag Italia Via Decembrio 28 20137 Milano springer.com

Foreword and Acknowledgements This book collects the main contributions to the research program Statistical design of the continuous product innovation carried out by a group of five units from the Italian Universities of Naples Federico II, Bologna, Salerno, Palermo and the Polytechnic of Turin, respectively. Some contributions are mainly applicative and concern the innovation of specific products or processes; other contributions are mainly theoretical and propose new methods to support the innovation process. All ones are aimed at showing that the technological innovation can be planned and designed likely any other product feature. Until the past century, firms gained competitive advantage from reducing costs, minimizing process variability and continuously improving their products. In the current global marketplace, these initiatives are only prerequisites to survive, while innovation is the actual source of competitive advantage. Product innovation is realized when the product is provided with a new feature aimed at fulfilling a new customer need. Since customer needs change rapidly over time, product innovation must be a continuous process and, consequently, it cannot rely on a brilliant and contingent intuition as for an invention. Often some needs are latent and cannot be elicited from a traditional customer survey, so they must be identified differently, by means of more advanced statistical tools. Sometimes, the innovation is implemented by exploiting a new technology, which is not necessarily the most advanced one, since its aim is fulfilling a new customer need not showing an intrinsic novelty. The above essential considerations are only examples of those developed by the contributions contained in this book. From the whole set of contributions a new approach to the innovation as a never-ending series of manufacturing cycles arises. Each cycle requires a series of steps, each performed using a specific statistical and/or engineering tool. The contributions result from different Statistics and Engineering schools, hence their whole set is not biased by any specific point of view. Different opinions that were not able to converge were left unchanged and, when possible, all were tested facing practical applications. Nevertheless, many unsolved questions arise, v

vi Foreword and Acknowledgements but these certainly will boost further research to advance the statistical and engineering knowledge addressed to innovation. A glance to the table of contents is the most effective way to master the whole range of practical and theoretical topics covered by this book. It starts from product innovation attained by engineering design in virtual reality; then shows examples of process innovation obtained integrating physical and simulation experiments; proposes a Bayesian approach to the innovation of the reliability and maintenance service; ends with an advanced approach to management of the research and innovation activities themselves. This book and the whole research program Statistical design of the continuous product innovation (PRIN 2005 2007) have been financially supported by the Italian Ministry of University and Scientific and Technological Research (MIUR). Naples, 24 August 2008 Pasquale Erto

Contents Part I Design for Innovation 1 Analysis of User Needs for the Redesign of a Postural Seat System.. 3 Stefano Barone, Alberto Lombardo, and Pietro Tarantino 1.1 Introduction.... 3 1.2 Evolution in the Customers Concept of Quality.... 4 1.3 Traditional Methods for Capturing Customers Needs... 6 1.3.1 VoiceoftheCustomer... 6 1.3.2 Quality Function Deployment..... 7 1.3.3 KanoModel... 8 1.3.4 KanseiEngineering... 9 1.4 Advanced Methods for Capturing Customers Needs... 10 1.4.1 IntegratingKanseiEngineering... 11 1.4.2 A New Practical Way to Measure Customer Preferences for Product Attributes... 12 1.4.3 A Simplified Version of the Kano Questionnaire..... 13 1.5 NeedsAnalysisfortheDesignofaPosturalSeatSystem... 15 1.5.1 Regulations and Figures on Disability... 15 1.5.2 ObjectivesoftheStudyandWorkPlan... 16 1.5.3 CustomerIdentification... 16 1.5.4 Benchmarking... 18 1.5.5 IdentificationofNeeds... 18 1.5.6 ImportanceofNeeds... 18 1.5.7 RelationModel... 20 1.5.8 Design Suggestions.... 22 1.6 Conclusions... 23 References... 24 vii

viii Contents 2 Statistical Design for Innovation in Virtual Reality... 27 Antonio Lanzotti, Giovanna Matrone, Pietro Tarantino, and Amalia Vanacore 2.1 Introduction....... 28 2.2 From Emotions to Innovation in Virtual Reality... 29 2.3 ThreeApplicationsofStatisticalDesignforInnovation... 32 2.3.1 RailwayCoachInteriorDesign... 32 2.3.2 RailwaySeatDesign... 33 2.3.3 PosturalSeatSystemInnovation... 36 2.4 Conclusions... 40 References... 41 3 Robust Ergonomic Virtual Design... 43 Stefano Barone and Antonio Lanzotti 3.1 Introduction....... 43 3.2 Aims and Phases of the Robust Ergonomic VirtualDesign(REVD)Strategy... 45 3.2.1 Key Steps of the Parameter and Adjustment DesignPhases... 46 3.2.2 AFirstApplication:Three-WheeledVehicle... 51 3.3 Anthropometric Noise Factor for a Mixture Population...... 55 3.3.1 A Second Application: Mini-Car User Packaging....... 56 3.4 AdjustmentDesignofaNewMini-CarDrivingSeat... 58 3.4.1 SensitivityofComfortLosstoMixVariation... 59 3.4.2 AdjustmentOptimization... 60 3.5 Conclusions... 62 References... 63 4 Computer Simulations for the Optimization of Technological Processes... 65 Alessandro Baldi Antognini, Alessandra Giovagnoli, Daniele Romano, and Maroussa Zagoraiou 4.1 Introduction....... 66 4.1.1 ImportanceofComputerSimulation... 66 4.1.2 SimulatorsandEmulators... 66 4.1.3 SequentialComputerExperiments... 67 4.1.4 StochasticSimulators... 68 4.2 ConstructionoftheEmulators... 69 4.2.1 AProtocolforCreatingEmulators... 69 4.2.2 A Special Type of Emulator: The Kriging Technique.... 70 4.2.3 AccuracyofthePredictor... 73 4.2.4 ExperimentsforaKrigingModel... 74 4.3 SequentialExperimentsforKriging... 76 4.3.1 DesignandAnalysisofSequentialExperiments... 76 4.3.2 Recent Developments in Sequential Computer ExperimentsforKrigingwithApplications... 78

Contents ix 4.3.3 Application-DrivenSequentialDesigns... 78 4.3.4 A Modified Version via Randomization... 79 4.4 Robust Parameter and Tolerance Design viacomputerexperiments... 81 4.4.1 Robust Parameter and Tolerance Design: CrossedArraysandCombinedArrays... 81 4.4.2 The Proposed Simulation Protocol and Its Application to the Integrated Design of Parameters and Tolerances... 82 4.4.3 AnApplicationtoComplexMeasurementSystems... 83 4.4.4 OtherPotentialApplications... 84 References... 86 Part II Technological Process Innovation 5 Design for Computer Experiments: Comparing and Generating Designs in Kriging Models... 91 Giovanni Pistone and Grazia Vicario 5.1 Introduction.... 91 5.2 KrigingPrediction... 93 5.3 AClassofDesigns:FractionsofaRegularGrid... 95 5.4 Comparing Different Designs: Cases 2 2, 3 3, 4 4... 96 5.4.1 3 3LHDesigns... 97 5.4.2 4 4LHDesigns... 99 5.5 Conclusions...100 References...101 6 New Sampling Procedures in Coordinate Metrology Based on Kriging-Based Adaptive Designs... 103 Paola Pedone, Daniele Romano, and Grazia Vicario 6.1 Introduction....103 6.2 KrigingModels...106 6.3 Prediction Capability: Kriging vs. Regression.....108 6.4 AdaptiveCMMInspectionPlans...112 6.5 Application to Straightness and Roundness.......115 6.5.1 Case1:Straightness...115 6.5.2 Case 2: Roundness....117 6.6 Conclusions...119 References...119 7 Product and Process Innovation by Integrating Physical and Simulation Experiments... 123 Daniele Romano 7.1 ExperimentsandInnovation...123 7.2 Physicalvs.ComputerExperiments...125 7.3 AnIntegratedApproach...127 7.4 Applications to Product and Process Development......129

x Contents 7.4.1 Product Innovation: The Climbing Robot.....130 7.4.2 ProcessInnovation:TheFlockingProcess...132 7.5 DiscussionandFutureDevelopments...141 References...142 8 Continuous Innovation of the Quality Control of Remote Sensing Data for Territory Management... 145 Elisabetta Carfagna and Johnny Marzialetti 8.1 Land-CoverDatabases...145 8.2 Quality of Land-Cover Databases...146 8.3 Statistical Quality Control by Acceptance Sampling...148 8.3.1 Classical Methods....148 8.3.2 Sequential Acceptance Sampling.......149 8.4 Examples of Quality Control and Land-Cover Databases Validation...150 8.4.1 The International Geosphere Biosphere Programme: GlobalLand-CoverDataSet...150 8.4.2 The Global Land Cover Map 2000 Validation and Quality Control....150 8.4.3 CORINELandCover...151 8.4.4 TheISTATExperiment...152 8.5 Unbiased Estimates of the Quality Parameters with Adaptive SequentialSampling...153 8.6 AnAdaptiveSequentialProcedure...155 8.7 Two-StepAdaptiveProcedure...155 8.8 Continuous Improvement of a Database of Remote Sensing Data. 156 8.9 ConclusionsandFutureDevelopments...158 References...159 9 An Innovative Online Diagnostic Tool for a Distributed Spatial Coordinate Measuring System... 161 Fiorenzo Franceschini, Maurizio Galetto, Domenico Maisano, and Luca Mastrogiacomo 9.1 Introduction.......162 9.2 The Concept of the Reliability of a Measurement....163 9.3 MScMS Technological and Operating Features...164 9.4 MScMS Diagnostic System...168 9.5 Energy Model-Based Diagnostics...169 9.5.1 Setting Up the Test Parameters...171 9.5.2 An Example of the Application of Energy Model-Based Diagnostics...172 9.6 Conclusions...175 References...175

Contents xi 10 Technological Process Innovation via Engineering and Statistical Knowledge Integration... 177 Biagio Palumbo, Gaetano De Chiara, and Roberto Marrone 10.1 Introduction....178 10.2 Technological Context and Case Study.....179 10.3 Pre-experimentalPlanning...180 10.4 ExperimentalDesignandSet-Up...182 10.5 Analysis of Results and Technological Interpretation....184 10.5.1 AnalysisofResults...184 10.5.2 Technological Interpretation of Results...186 10.6 Conclusion...189 References...189 Part III Innovation of Lifecycle Management 11 Bayesian Reliability Inference on Innovated Automotive Components... 193 Maurizio Guida and Gianpaolo Pulcini 11.1 Introduction....193 11.2 Prior Inference on the Failure Probability...195 11.2.1 PastData...195 11.2.2 FormalizingModificationEffectiveness...195 11.2.3 EffectofWorkingConditionsandCostReduction...196 11.2.4 Prior Inference on the Failure Probability of the New Product....199 11.2.5 PriorPredictionoftheNumberofFailedItems...201 11.3 Field Failure Data for the New Product.....202 11.4 Posterior Inference on the New Product.....204 11.4.1 Posterior Inference on the Reliability....204 11.4.2 PosteriorPredictionoftheNumberofFailedItems...205 11.5 ACaseStudy...205 11.6 Conclusions...209 Appendix...210 References...210 12 Stochastic Processes for Modeling the Wear of Marine Engine Cylinder Liners... 213 Massimiliano Giorgio, Maurizio Guida, and Gianpaolo Pulcini 12.1 Introduction....213 12.2 The Case Study: System Description, Technological Information andexperimentaldata...215 12.3 FormulatingtheModels...217 12.3.1 Model 1: Shock Model with a Deterministic andconstanteffect...217 12.3.2 Model2:GammaWearProcess...219 12.3.3 Model3:State-DependentMarkovWearProcess...220

xii Contents 12.4 NumericalApplicationandResults...222 12.5 Conclusions...226 A Appendix:EstimationProcedures...227 A.1 PLShockModel...227 A.2 GammaProcess...228 A.3 PoissonMarkovProcess...229 References...229 Part IV Research and Innovation Management 13 A New Control Chart Achieved via Innovation Process Approach... 233 Pasquale Erto and Giuliana Pallotta 13.1 Introduction.......233 13.2 IdentifyingtheNewNeededEstimationFeatures...234 13.3 DevelopingtheInnovativeEstimationProcedure...237 13.3.1 First Innovation Step: A Shewhart-Type Control Chart of the Weibull Percentile...237 13.3.2 Second Innovation Step: A Bayesian Cumulative Control Chart of the Weibull Percentile......241 13.3.3 Third Innovation Step: A Bayesian Cumulative and Adaptive Control Chart of the Weibull Percentile... 243 13.4 Conclusions...244 References...244 14 A Critical Review and Further Advances in Innovation Growth Models... 247 Pasquale Erto and Amalia Vanacore 14.1 Introduction.......247 14.2 A Comparison Among Different S CurveModels...248 14.3 CriteriaUsedtoComparetheModels...250 14.3.1 Consistency of the Properties of the Model with the Dynamics of Technological PerformanceGrowth...251 14.3.2 The Stability of Least Squares Estimates Versus Different Assumptions About the Error Term......252 14.3.3 Sustainability of the Assumption of Linearity...... 255 14.3.4 Seeking a Good Reparameterization for the Generalized WeibullModel...256 14.3.5 The Goodness of Fit of Each Model....258 14.4 Conclusions...259 References...260 Index...261

List of Contributors Baldi Antognini, Alessandro Department of Statistical Sciences, University of Bologna e-mail: a.baldi@unibo.it Barone, Stefano Department of Technology, Production and Managerial Engineering, University of Palermo, Viale delle Scienze, 90128 Palermo e-mail: stefano.barone@unipa.it Carfagna, Elisabetta Department of Statistical Sciences, University of Bologna e-mail: elisabetta.carfagna@unibo.it De Chiara, Gaetano AVIO S.p.A., Manufacturing Technologies Department, Pomigliano, Naples, Italy e-mail: gaetano.dechiara@aviogroup.com Erto, Pasquale Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125, Naples, Italy e-mail: pasquale.erto@unina.it Franceschini, Fiorenzo Department of Production Systems and Business Economics (DISPEA), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy e-mail: fiorenzo.franceschini@polito.it xiii

xiv List of Contributors Galetto, Maurizio Department of Production Systems and Business Economics (DISPEA), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy e-mail: maurizio.galetto@polito.it Giorgio, Massimiliano Department of Aerospatial and Mechanical Engineering, Second University of Naples, 81031 Aversa (NA), Italy e-mail: massimiliano.giorgio@unina2.it Giovagnoli, Alessandra Department of Statistical Sciences, University of Bologna e-mail: alessandra.giovagnoli@unibo.it Guida, Maurizio Department of Information Engineering and Electrical Engineering, University of Salerno, 84084 Fisciano (SA), Italy e-mail: mguida@unisa.it Lanzotti, Antonio Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125 Naples, Italy e-mail: antonio.lanzotti@unina.it Lombardo, Alberto Department of Technology, Production and Managerial Engineering, University of Palermo, Viale delle Scienze, 90128 Palermo e-mail: alberto.lombardo@unipa.it Maisano, Domenico A. Department of Production Systems and Business Economics (DISPEA), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy e-mail: domenico.maisano@polito.it Marrone, Roberto AVIO S.p.A., Manufacturing Technologies Department, Pomigliano, Naples, Italy e-mail: roberto.marrone@aviogroup.com Marzialetti, Johnny Department of Statistical Sciences, University of Bologna e-mail: johnny.marzialetti@unibo.it

List of Contributors xv Mastrogiacomo, Luca Department of Production Systems and Business Economics (DISPEA), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129, Torino, Italy e-mail: luca.mastrogiacomo@polito.it Matrone, Giovanna Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125 Naples, Italy e-mail: giovanna.matrone@unina.it Pallotta, Giuliana Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125, Naples, Italy e-mail: g.pallotta@unina.it Palumbo, Biagio Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125, Naples, Italy e-mail: biagio.palumbo@unina.it Pedone, Paola INRIM (Italian National Research Institute of Metrology), Strada delle Cacce, 91, 10135 Torino, Italy e-mail: p.pedone@inrim.it Pistone, Giovanni Politecnico di Torino, Department of Mathematics, Corso Duca degli Abruzzi, 24, 10129 Torino, Italy e-mail: giovanni.pistone@polito.it Pulcini, Gianpaolo Istituto Motori, National Research Council, 80125 Napoli, Italy e-mail: g.pulcini@im.cnr.it Romano, Daniele Department of Mechanical Engineering, University of Cagliari, Piazza d Armi, 1, 09123 Cagliari, Italy e-mail: romano@dimeca.unica.it

xvi List of Contributors Tarantino, Pietro Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125 Naples, Italy e-mail: pietro.tarantino@unina.it Vanacore, Amalia Department of Aerospace Engineering, University of Naples Federico II, P. le Tecchio 80, 80125 Naples, Italy e-mail: amalia.vanacore@unina.it Vicario, Grazia Politecnico di Torino, Department of Mathematics, Corso Duca degli Abruzzi, 24, 10129 Torino, Italy e-mail: grazia.vicario@polito.it Zagoraiou, Maroussa Department of Statistical Sciences, University of Bologna e-mail: maroussa.zagoraiou@unibo.it