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It is in the first two stages that the designer can reduce the greatest product cost by creating an effective functional design. The third stage is tolerance design to establish the acceptable tolerances around each parameter. The third stage is where most of the product cost is added in order to meet compliance. Because the company is not able to inspect each product individually it is important that the company focuses on minimizing variability in the product through process design and control of processes. But not all variability is controllable. "Products need to be designed so that they are robust ? their performance is insensitive to this naturally occurring, difficult to control variation...
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