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Presented by:
Randy Cooper, LeanSigma® Blackbelt &
Director of R&D
Maytag Jackson Dishwashing Products
Jackson, Tennessee
LeanSigma® Defintion
LeanSigma® is ….
Integrated processes
DFLS Mission Statement
DFLS
Using a system of defined processes and problem solving
tools to identify the Customer Needs and translate
them into System, Sub-System, and Part specifications.
The end goal is to create value for the customers while
maintaining the cost effectiveness of the products
Why DFLS?
From To
• Evolving Requirements • CTQ Flowdown
• Design Rework/Tweaking • Control Critical Parameters
• Modeling and Simulation with
• Build and Test
process capability flow up
• Measurement • Statistical Quality Prediction
• Test in Quality • Designed in Quality
New Product Development Process
ch
Ph-0 Ph-1 Ph-2 Ph-3 Ph-4 Ph-5
un
Market Concept Product Production Post Launch
La
Feasibility Feasibility Design Preparation Launch Review
• Smart Simple
Design Formulate Concept Design
Product
Technical Responses Definition
Sub-System
Specifications
Customer Needs
Sub-System Responses
Critical
Component
Technical Res. Specifications
Part Features
Sub-System Res.
Mfg. Processes
Part Features.
Drives Customer
Process
Needs to the Specifications
Factory Floor
Score Cards - Sigma Work Sheets
PARTS
Owner
Total
DPMO
Zlt Zst Status
Critical
Characteristics
(Opportunities)
Status
"Red" (<3.0)
Status
"Yellow"
Status
"Green"
(>4.0)
Purpose
To Record and
Monitor the CTQs
Summary 0.0000 Green 0 0
#DIV/0!
0
#DIV/0!
0
#DIV/0! Predict Design
Performance
PROCESS Critical Status
Quality
Total Status Status
Owner Zlt Status Characteristics "Green"
DPMO "Red" (<3.0) "Yellow"
(Opportunities) (>4.0)
2 P (production preparation)
Used anytime there is a change
Kaizen Interventions
ch
Ph-0 Ph-1 Ph-2 Ph-3 Ph-4 Ph-5
un
Market Concept Product Production Post Launch
La
Feasibility Feasibility Design Preparation Launch Review
2P
3P
3P 2P
DFMA
Concept
development
Develop a
business
case
VOC
Toll Toll Toll Toll Toll Toll
Gate Gate Gate Gate Gate Gate
0 1 2 3 4 5
Idea
Why use 2P/3P Processes?
Create
Train Evaluate Simulate Select
Alternatives
“Beginning
Mindsets”
New Product Development Process
ch
Ph-0 Ph-1 Ph-2 Ph-3 Ph-4 Ph-5
un
Market Concept Product Production Post Launch
La
Feasibility Feasibility Design Preparation Launch Review