Design For Six Sigma

DESIGN FOR SIX SIGMADEFINED

The Concurrent Development and Introduction of a new or radically redesigned product or service and all of the processes (Design, Procurement, Production, Logistics and Distribution, Service and Sales) that enable the product or service to achieve Six Sigma business performance. A Phased Methodology which includes both the design tools and innovative tools for designing products (goods, information or services) and processes that generate customer value. The phases are Define, Measure, Analyze, Design, Verify

INNOVATIVE DESIGNS FOR SIX SIGMADEFINED

MARKET RESEARCH
DESIGN PRODUCTION LOGISTICS DISTRIBUTION

DMADV

SERVICE SALES

CUSTOMERS

WHAT IS DESIGN FOR SIX SIGMA (DFSS)?

Customer-driven design of processes with 6 capability. Predicting design quality up front. Top down requirements flowdown (CTQ flowdown) matched by capability flowup. Cross-functional integrated design involvement. Drives quality measurement and predictability improvement in early design phases. Utilizes process capabilities to make final design decisions. Monitors process variances to verify 6 customer requirements are met.

THE DMADV METHODOLOGY AND TOOLS

DESIGN FOR SIX SIGMA
Understand customer needs and specify CTQs Develop design concepts and highlevel design Develop detailed design and control/test plan Test design and implement full-scale processes Initiate, scope, and plan the project

Define

Measure

Analyze

Design

Verify

DELIVERABLES
Team Charter CTQs High-level Design Detailed Design Pilot

TOOLS
Mgmt Leadership Project Customer Research QFD Benchmarking FMEA/Errorproofing Process Simulation Design Scorecards

Management

Benefits of DFSS

Cost reduction, Break-throughs / Discoveries, Warrantees, Recalls, New Designs, Patent Circumvention, Failure analysis, Failure prediction, Reliability, EHS, Training

I-DFSS DESIGN PROJECT

CASE 1
DPMO COPQ DPMO COPQ

CASE 2

CASE 3
No Current Product or Process

Current Product

Current Product

New Product

But: CTQs

Current Processes Design Cp, Cpk COPQ Manufacturing Distribution Service Marketing

New Processes

New Processes

High-level Design

CTQ GAP Base Line Performance

Design Scorecard

REDESIGN Base Line Performance OK

NEW PROCESS DESIGN Product Base Line Performance OK (May be of little value)

NEW PRODUCT AND PROCESS DESIGN No Base Line Performance

SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATION

Directed Evolution DE Anticipatory Failure Determination
Failure Analysis Strategically Evolving Future Generations of Technologies & Systems

AFD

IPS

Inventive Problem Solving

Surgical Removal of Tough Technological Problems

Failure Prediction

Invention of Failure Modes

Elimination of Contradictions

Pre-DEFINE Phase
HOW TO THINK ABOUT DFSS/NEW PRODUCT INTRODUCTION (NPI) Directed Evolution (DE)
Strategic vision Logical chain of product concepts Product evolution roadmap

DEFINE Phase
ESTABLISH DESIGN PROJECT FINANCIAL ANALYSIS PROJECT MANAGEMENT AND RISK ASSESSMENT SUMMARY; ISSUES TO CONSIDER

MEASURE Phase
ESTABLISH CTQs AND CTIs Innovation Situation Questionnaire & Problem Formulator
Design problem documentation Design expectations

INTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTION MSA (Variables, Attribute and Data quality) PROCESS CAPABILITY (Variables and Attribute) RISK ASSESSMENT Anticipatory Failure Determination (AFD)
Failure prediction

DESIGN SCORECARD

ANALYZE/HIGH-LEVEL DESIGN Phase

DEVELOP DESIGN ALTERNATIVES Innovative Problem Solving (IPS)
Description of design options (alternatives) Analysis of design alternatives for technological barriers and contradictions

DEVELOP HIGH-LEVEL DESIGN (VA/VE) MULTI-VARIATE ANALYSIS CONFIDENCE INTERVALS AND SAMPLING HYPOTHESIS TESTING AND ANOVA EVALUATE HIGH-LEVEL DESIGN Anticipatory Failure Determination (AFD)
Failure analysis and prediction

DETAIL DESIGN Phase

RISK ASSESSMENT/FALURE ANALYSIS Anticipatory Failure Determination (AFD)
Failure analysis

TAGUCHI METHODS AND ROBUST DESIGN TOLERANCING DOE with RSM

DETAIL DESIGN Phase (contd)

RELIABILITY and AVAILABILITY NON-PARAMETRIC STATISTICS SIMULATION with Monte Carlo Methods DESIGN FOR MANUFACTURABILITY/DESIGN FOR ASSEMBLY DVT/TESTABILITY DESIGN SCORECARD

DETAIL DESIGN Phase -- CUSTOM FEATURES

THE TOOLS OF DETAIL DESIGN CONCURRENT ENGINEERING SOFTWARE ENGINEERING METHODS AND TOOLS (CMM, CASE)
ENHANCED DESIGN FOR: Commercial/Competitive Success Manufacturability Serviceability Reliability Availability Information Management Control

VERIFY Phase
DESIGN FOR CONTROL DESIGN FOR MISTAKE- AND FOOLPROOFING STATISTICAL PROCESS CONTROL (SPC) MVT TRANSITION TO PROCESS OWNERS Directed Evolution (DE)
Logical sequence of new scenarios Strategic knowledge base and patent portfolio Targeted competitive intelligence New product evolutionary stages

SUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURE

VERIFY Phase - PILOT TESTING FULL-SIZE SCALE-UP AND

COMMERCIALIZATION DESIGN INFORMATION AND DATA MANAGEMENT LEAN MANAGEMENT

 DMADV Training/Project Map

IDEAL
Training

15 - 16 Weeks

D-M
1 3

A
1 4

D
1 4-6

V
1 4-6

Weeks

Project

D-M

PP

DR-2

DR-3 DVT

DR-4 MVT

19 - 22 Weeks (5-6 Months)

Critical Success Factors: Project starts with training Project < 6 months Project phases match training schedule

SIX SIGMA DMADV TRAINING FLOW

Executive Briefing Preparations Champion Training/Workshop Go-No go Decision

DMADV

Black Belt Training Define/Measure Analyze Design Verify

Trained Black Belt

Black Belt Project

D/M A D

No

Certified Black Belt

Yes

Certification Project

Statistics, Finance Leadership Skills

Master Black Belt Program

Master Black Belt Project

Certified MBBs