Application of House of Quality in the Design Requirements for

Flakes Machines in the Banana Flakes Production Process

Aidil Haryanto and Novrinaldi

Research Center for Appropriate Technology, Indonesian Institute of Sciences, KS Tubun street, Subang, Indonesia

Keywords: Banana Flakes, Design Requirement, Flakes Machine, House of Quality, Quality Function Deployment.

Abstract: Banana flakes are products with the main ingredients that contain ripe banana flour. The use of ripe banana

flour will make the dough sticky and mushy, which is a problem in the banana flakes production process.

These problems are such as the difficulty in the process of forming dough sheets, the process of cutting flakes,

and the sticky dough on the tool. Therefore, to solve these problems need planning and problem solving based

on customer requirements to design flakes machine. To identify design requirements based on these problems

using one of the planning phases of quality function deployment (QFD), called the house of quality (HOQ).

HOQ is a planning and problem-solving tool for the design team that functions to provide input into the design

process phase. The application of HOQ focused the design team's attention on customer satisfaction during

the product design and development process. HOQ gives relationship matrix between customer requirements

(CRs) and engineering characteristics (ECs) that will produce recommendations and constraints that must be

considered when designing a product. Based on the application of HOQ revealed that there are three highest

ranks of a total of 17 ECs, namely the production time of 13.44%, the automation of machine of 11.46%, and

the production capacity of 10.05%, its means that the design focus for flakes machine must lead based on the

analysis.

1 INTRODUCTION

Banana is a horticultural commodity that grows in

Indonesia. Indonesia has almost 200 types of bananas

(Fatmawati and Dianawati, 2016). Bananas contain

carbohydrates 22.84 g/100 g, vitamin C 8.7 mg/100

g, and minerals (potassium 358 mg, magnesium 27

mg, phosphorus 22 mg, calcium 5 mg, sodium 1 mg,

and iron 0.26 mg per 100 g) (Mahmudah, Amanto and

Widowati, 2017). Other than that, bananas contain

prebiotics and have benefits for the human

(Desnilasari and Lestari, 2014). One of

diversification of the production process of bananas

is banana flour (Surahman et al., 2019). One of the

products of banana flour processing is banana flakes.

Banana flakes are flakes food products from ripe

banana flour which is an alternative for breakfast

(Setyadi, 2016; Surahman et al., 2019).

However, the production process of banana flakes

made from ripe bananas has constraints in increasing

production capacity caused by dough sticky and

mushy. Some banana flakes production processes still

use simple and manual equipment. To design the

machine flakes in the banana flakes production

process needs some initial analysis in solving

problems based on customer requirements (CRs) with

the identification method of the design requirements

using one of the planning phases of the QFD, called

the HOQ (Dieter and Schmidt, 2013). Regarding the

methods for designing the new product development,

Quality Function Deployment (QFD) is a significant

methodological approach to enhance customer

satisfaction and reduce the production costs (Zadry et

al., 2015). QFD has been profitably applied by

industries around the world (Dieter and Schmidt,

2013; Zadry et al., 2015). The objective of this paper

with HOQ methods is to give relationship matrix

between CRs and engineering characteristics (ECs)

that will produce recommendations and constraints

which must be considered when designing the

product.

2 MATERIALS AND METHODS

In application HOQ, there are two sides to the

analysis. The first is collecting data to identify

customer preferences for banana flakes product

284

Haryanto, A. and Novrinaldi, .

Application of House of Quality in The Design Requirements for Flakes Machines in The Banana Flakes Production Process.

DOI: 10.5220/0009982100002964

In Proceedings of the 16th ASEAN Food Conference (16th AFC 2019) - Outlook and Opportunities of Food Technology and Culinary for Tourism Industry, pages 284-288

ISBN: 978-989-758-467-1

characteristics (Zadry et al., 2015; Djekic et al.,

2017). The second is comparing CRs that have been

obtained from the analysis results of data collection

with ECs (Dieter and Schmidt, 2013).

2.1 Preliminary Study

Preliminary study on the QFD concept was conducted

observations and interviews directly with customers

(Zadry et al., 2015). In this case, customers are the

makers of banana flakes or the producer banana

flakes. Interviews were conducted to obtain

information based on complaints that occurred. The

interview is the initial stage which aims as a reference

in designing the questionnaire and an initial

description of the needs and expectations of

customers to design machine flakes in the banana

flakes production process.

2.2 Customer Requirements Data

Collection

Data collection was carried out using a questionnaire.

Questionnaires are distributed to customers to find

out what complaints and customer needs regarding

the production process that is being used as well as

the expected production process. The use of

questionnaires is also used to find out ideas related to

the design of flakes machines (Zadry et al., 2015).

The questionnaire was developed based on interview

data and direct observations that refer to the quality

dimension (Dale, 2003). Grouping CRs include

performance, durability, reliability, features, and

aesthetics. Questionnaires based on CRs were given

from least important (1) to most important (5).

2.3 Concept of QFD

QFD is a systematic approach that focuses on the

initial design of the design team on user satisfaction

to make a machine that can work according to CRs

(Dieter and Schmidt, 2013; Prasad and Chakraborty,

2013). The complete QFD process is diagrammed in

Figure 1, Figure 2, Figure 3, and Figure 4. That

figures is the four phases of QFD process (Tsai et al.,

2008).

The QFD process consists of four phases that are the

steps towards accountable design results. The results

of each phase becoming the input to the next (Dieter

and Schmidt, 2013). The initial stage of the QFD is

that HOQ serves to guide the design team in

determining the ECs that have the most influence

on CRs. The basic translation of CRs into ECs can be

Figure 1: Phase 1. House of quality.

Figure 2: Phase 2. Part of deployment.

Figure 3: Phase 3. Process planning.

Figure 4: Phase 4. Production planning.

accomplished with a HOQ consisting of Rooms 1, 2,

4, and 5 (Dieter and Schmidt, 2013). Room 3

correlation matrix can be added to find out the

correlation on ECs for design consideration.

The HOQ matrix is introduced as follows:

Functions in Room 1 represent needs or desires from

customers. Based on their desires, the customers may

give different importance rating (Chen et al., 2017).

ECs in Room 2 are product performance measures

and features that have been identified. ECs include

production need, engineering analysis, and key part

Application of House of Quality in The Design Requirements for Flakes Machines in The Banana Flakes Production Process

285

reliability. ECs are usually measurable values and

their units are placed near the top of Room 2. Symbols

indicating the preferred improvement direction of

each EC are placed at the top of Room 2. Thus a ↑

symbol indicates that a higher value of this EC is

better, and a ↓ symbol indicates that a lower value is

better. It is also possible that an EC will not have an

improvement direction (Dieter and Schmidt, 2013).

The Correlation matrix in Room 3 shows the degree

of dependence among the engineering characteristics

in the roof of the HOQ. It is best to recognize these

correlated relationships early so that appropriate

trade-offs can be made during embodiment design.

The correlation matrix shows that there are strong

positive correlations (indicated by “++”), positive

(indicated by “+”), negative (indicated by “-”), and

strong negative (indicated by “--”) among EC pairs.

In the Room 4, the Relationship matrix is at the

center of an HOQ. Each cell in the matrix is marked

with a symbol that indicates the strength of the causal

association between the EC of its column and the CR

of its row. The scoring scheme for each cell is given

as a set of symbols that represent an exponential range

of numbers (9, 3, 1, and 0). The EC will contribute to

fulfilling the CR in the cell’s row significantly (9),

moderately (3), or slightly (1). The cell is left blank if

the EC has no impact on the CR (Dieter and Schmidt,

2013). Importance ranking in Room 5 present priorities

and goals for product design or improvement. They

summarize basic data representing CRs and can help

indicate strategic opportunities (Ramírez, Cisternas

and Kraslawski, 2017).

The procedures of the traditional HOQ chart of

QFD are divided into the following five steps (Figure

5). Step 1: Identifying the CRs, step 2: Determining

ECs, step 3: Determining correlation matrix, step 4:

Translating CRs into measurable ECs, and step 5:

Setting engineering targets for the design.

Figure 5: The HOQ matrix (Dieter and Schmidt, 2013).

3 RESULT

3.1 Customer Requirement Analysis

The first stage in the HOQ analysis is to identify

customer needs so that it can produce flakes machine

design based on needs. CRs based on the results of

the questionnaire is importance rating rate, which is

the average rating of all respondents or users. Table 1

shows the classification of customer requirements

based on observations and interviews conducted.

Table 1: Classification of customer requirements based on

observations and interviews conducted.

Criteria

Customer

requirements

Importance

rating rate

Performance

Scaling up

4.6

Reduce manual

production process

4.4

Integrated with

existing systems

4.4

Durability Continuously

Reliability

Operated for mushy

and sticky dough

4.6

Make the thin sheets

dough

4.4

Easy to use

4.6

Features

Produce uniform

products

Replace the manual

flakes cutting

process

Reducing the stages

of the production

process

4.4

Hygiene Products

4.8

Easy to carry and

move

3.6

Conformance

Minimize noise

Energy saving

2.4

Serviceability Materials availability

1.4

3.2 HOQ

3.2.1 Engineering Characteristics

HOQ is generated by connecting CRs with ECs. ECs

are carried out in consultation and discussion by the

design team based on CRs. Symbols (↑ and ↓) on ECs

indicate improvement direction. ECs for machine

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flakes in the banana flakes production process can be

grouped into three categories such as Table 2.

Table 2: Engineering characteristics.

Categories

Engineering

characteristics

Units

Imp.

direction

Production

needs

Production

capacity

Kg/

batch

↑

Production time s ↓

Automation of

machine

n/a ↑

Engineering

analysis

Material

selection of

machine

n/a -

Manufacturing

process

selection

n/a -

Safety factor n/a ↑

Dimension of

machine

m ↓

Mass of

machine

Kg ↓

Life time cycle ↑

Force N ↓

Vibration

frequency

Hz ↓

Material

strength

MPa ↑

Energy

consumption

n/a ↓

Assembly n/a -

Maintenance n/a ↓

Dough

properties

Product

viscosity

Pa.s ↑

Product density Kg/m

↓

3.2.2 HOQ Matrix for Flakes Machine in

the Banana Flakes Production Process

By applying the QFD method, a HOQ is built as

shown in Figure 6.

4 DISCUSSION

For the case of HOQ, the decision-making process is

supported by straightforward specification of CRs

(Ramírez, Cisternas and Kraslawski, 2017). It results

in the identification of suggested changes to the

analyzed technology. The application of HOQ in the

design of flakes machine in the banana flakes

production process resulted in 17 ratings according to

the number of ECs. Figure 3, rank order is generated

from a percentage from the highest to lowest relative

weight. Based on the relationship between CRs and

ECs shows that the three highest-ranking according to

the customers are production time of 13.44%,

automation of machine of 11.46%, and production

capacity of 10.05%, its means that the design focus

for flakes machine must lead based on the analysis.

The highest-ranking ECs from the HOQ are either

constraints or design variables whose values can be

used as decision-making criteria for evaluating

candidate designs. There are certain design

parameters that can only take a few discrete values. If

so, the design team should review the possible values

of the EC, determine which is best at meeting

correlated EC targets of the design, and then use only

the selected value of the EC in generating conceptual

designs. The results from the HOQ act as a guide to

assist the team in determining the selection criterion

for evaluating designs. However, in designing the

machine flakes need to consider other ECs to meet

customer satisfaction. The lowest-ranking ECs of the

HOQ are not as critical to the success of the design.

These ECs allow freedom during the design process

because their values can be set according to priorities

of the designer.

The three highest ranks indicate that users need a

machine that can streamline the banana flakes

production process and improve the quality and

quantity of banana flakes products. The three highest

ranks are in the category of production needs in ECs.

Caused by the majority of respondents only being

customers or operators of flakes machines. This

information allows a design team to allocate design

resources to the product performance aspects or

features (ECs) that are most critical to the success of

the product. These can be called critical to quality

engineering characteristics or CTQ ECs.

5 CONCLUSIONS

In determining the design requirements for machine

flakes by using or implementing HOQ it produces

recommendations and constraints that must be the

main focus. HOQ which is a matrix of the relationship

between CRs and ECs for designing machine flakes

in the production process of banana flakes.

Distributing relative weight (%) scores shows

scores ranging from lowest to highest for ECs. The

higher the percentage of the relative weight obtained,

the more ECs require special attention. HOQ matrix

for flakes machine produces three main

recommendations and constraints as explained in the

discussion section that is the focus of design.

Application of House of Quality in The Design Requirements for Flakes Machines in The Banana Flakes Production Process

287

Figure 6: HOQ matrix for flakes machine in the banana flakes production process.

ACKNOWLEDGEMENTS

Thanks are due to Research Center for Appropriate

Technology-Indonesian Institute of Sciences and

Ministry of Research, Technology and Higher

Education of the Republic of Indonesia.

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