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Design for Six Sigma Innovation for Enhanced Competitiveness [Submitted Manuscript to GOALQPC] Design for Six Sigma Innovation for Enhanced Competitiveness [Submitted manuscript to GOALQPC] GREGORY H. WATSON 2005 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM Word Count: 129377 DESIGN FOR SIX SIGMA Innovation for Enhanced Competitiveness Gregory H. Watson GOAL / QPC Press Salem, New Hampshire 2005 Page 1 of 345 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM For ‘maya solnushka’ Crista, who is learning much too early that growing up is ‘so very hard to do.’ Page 2 of 345 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM Table of Contents Page Preface Foreword - Setting the Stage for Six Sigma Designs Chapter 1 - Introducing Design for Six Sigma Chapter 2 - Managing Design Programs Chapter 3 - Managing Product Design Projects Chapter 4 - Measuring Program and Project Progress Chapter 5 - Engineering Value into Designs Chapter 6 - Planning Innovative Design Developments Chapter 7 - Building Reliability into Products Chapter 8 - Experimenting to Create Robust Performance Chapter 9 - Controlling Product Realization Afterword - Charting the Direction of Six Sigma Appendix A: Evaluating Your Readiness for Design for Six Sigma Appendix B: Preliminary Design for Six Sigma Body of Knowledge Appendix C: Data Analysis and Experimentation Appendix D: References About the Author Index Page 3 of 345 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM Preface “There is no substitute for process knowledge.” ~ W. Edwards Deming Design for Six Sigma - A Birth of Necessity Design for Six Sigma (DFSS) is truly an evolving discipline. DFSS evolved out of an operational business requirement - the need to move product quality beyond the 4.5 sigma barrier that is often created because the base design of products is unable to support a higher quality performance. In order to achieve higher quality levels, it became recognized that total rethinking of the design - leading to a redesign - was essential. It became clear to the early practitioners of Six Sigma that the statistical problem-solving process (this process is typically called DMAIC - an acronym that summarizes its five steps of define, measure, analyze, improve and control) needed adaptation to serve this application of product development. Further, it became clear that this methodology did not fit a ‘one-size-fits-all’ process description. Customization was required to fit business environments, corporate cultures, regulatory compliance requirements, industry- specific norms and that DFSS needed to be integrated into the new product development or product creation process for very different applications (e.g., design of hardware, software and services). Perhaps the combination of a pressing business need and unclear operational definition have kept Six Sigma both at the front-of-mind for business leaders while concurrently frustrating them that the thought leaders in the support community of consultants and academics could not provide better guidance. Purpose of this Book The objective of this book is expansive - it seeks to establish a comprehensive overview of DFSS for an audience of business leaders. This book seeks a balance between a populist book that ends up doing no more than cheer-leading and a detailed textbook that is targeted at implementers and tool users but drowns the reader in its details. It also seeks to fill a gap that is perceived in previous books on this subject 1 by purposefully focusing upon its targeted customer as the business leader who needs to have the subject of DFSS demystified and providing a coherent, comprehensive manuscript that would clarify the DFSS concept thereby serving as a beacon to organizations interested in navigating these improvement waters. The roots of this book are in 1 Previous books on this subject include: Subir Chowdhury, The Power of Design for Six Sigma (Dearborn, MI: Dearborn Trade, 2002); Clyde M. Creveling, Jeffrey L. Slutsky, and David Antis, Jr., Design for Six Sigma in Technology and Product Development (Upper Saddle River: Prentice-Hall, 2003), Kai Yang and Basem El-Haik, Design for Six Sigma: A Roadmap for Product Development (New York: McGraw-Hill, 2003); Greg Brue, Design for Six Sigma (New York: McGraw-Hill, 2003); Dana Ginn and Barbara Streibel, The Design for Six Sigma Memory Jogger (Salem, NH: GOAL/QPC Press, 2004). Page 4 of 345 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM articles written for Quality Progress, Six Sigma Forum Magazine, Manufacturer’s Monthly and speeches at numerous conferences over the past seven years and the author’s experience in product development at Hewlett-Packard, Compaq, Xerox and Nokia. The book itself has been borne out of two and a half years of thinking, writing, brooding, rewriting, and editing. This has been a tough project - perhaps for the same reasons, others have had in characterizing this subject. This work is unfinished. It will remain unfinished because the real work is not in the writing of a book but in transitioning these ideas and tools into the business environment of a firm and making a difference in the way that it defines and introduces its new products and thereby serves its customers. Acknowledgements I owe a debt of gratitude to the many people who have challenged my thinking and encouraged me to pursue this project - and in advance I ask the reader’s forgiveness as I practice the ‘Oscar’ appreciation syndrome! So, I say ‘thank you!’ • Most especially to my long-suffering and loyal business partner of over ten years, Jeff Martin and his most supportive and loving family. • To the many clients and professional colleagues who have challenged and stimulated my thinking and assisted me on my journey: Pekka Ala-Pietilä, Timo Hannukainen, Simo Salminen, Ahti Vaisenen, Perti Korhonen, Phil O’Neil, Raija Pollanen and Kirsi Allonen (Nokia Group); Bob Peterson, Brian Fischer, Tony Abraham, Claude Pidgeon, Phil Valance, David Sims, David Cox, and Aldous Wong (ExxonMobil); Taizo Nishimuro and Hitoche Ootsuka (Toshiba); Mark Leidy, Ron Cooley, Deb Small, Randy White, George Brazuk, Matt Barrows, Ty Whitten, Rick Simmons, Fred Verner, Clive Deetlefs and Neil Anderson (Monsanto); Matti Toivianen (KCI Konecranes); Larry Smith (Ford); as well as Bill Grundstrom, Joe Wexler and Harvey Brelin (Dell Computer). • To my colleagues in the Industrial Engineering and Management Department of Oklahoma State University: Bill Kolarik, Ken Case, Paul Rossler, Camille DeYoung, Brenda Johnson and Amanda Holley and to the Halliburton Foundation for supporting the development of the graduate programs in engineering and technology management through their generous grants. • To my students: thanks for making me think anew and providing a constant and provoking forum for sharpening the blunt instrument of my mind. • To my colleagues and subject matter experts in “The Gathering:” Richard Zultner, John Terninko, Tony Rizzo, and Glenn Mazur - you’ve all made a fantastic contribution to the advancement of DFSS. • To some special friends who have helped and encouraged me over the years: Katarina Von Firks, Bea Alanko and Frank Toda - thanks for being there! • To my colleagues, mentors and friends in Japan: Yoshio Kondo, Takanori Yoneyama, Yoji Page 5 of 345 Design for Six Sigma: Innovation for Enhanced Competitiveness GOAL/QPC Manuscript - Submission Version Created: November 9, 2004 3:50 AM Gregory H. Watson Last Revised: 6/12/2019 8:23 PM Akao, Noriaki Kano, Genichi Taguchi, Kenzo Sasaoka and Katsu Yoshimoto. • To my colleagues and friends in Mexico: Gumersindo Montemayor, Moises Sandler, Humberto Canto, Xavier Lozano, Rodrigo Plancarte de la Garza, Leopoldo Pompa, Orlando Valencia and Jose Luis Dias. • To my colleagues in Australia: Christopher F. Brendon and Michael A. Sargent. • To my special friends in the world’s quality community: Bertrand Jouslin de Noray (European Organization for Quality), Gennady Voronin and Natalia Tompson (Russian Organization for Quality), Frank Steer (Institute for Quality Assurance), Paul O’Grady and Anne Marie Fallon (Excellence Ireland Quality Association), Lincoln Sim and Ken Liang (Singapore Quality Institute), Jorge Gerdau Johannpeter (Movement Quality Brazil), and, especially, Risto Lintula (Center for Excellence Finland). • To my colleagues in the International Academy for Quality (not otherwise named): Armand V. (Val) Feigenbaum, Marcos Bertin, Spencer Hutchins, John Hromi, David Luther, Lennart Sandholm, Tito Conti, Juhani Anttila, Bob Cole, Jens Dahlgaard, Miflora Gatchalian, Bland Godfrey, Jim Harrington, Jean-Claude Savard, Ken Stevens,Shoji Shiba, and Liz Keim. • To my colleagues at the American Society for Quality: Paul Borawski, Bill Tony, Catherine Valentine, Erin Hogg, Karen Prosser, Linda Zysko, Annemmieke Hytinen and the cast of hundreds of staff and board members who made my experience as president so memorable. • To my publisher and friend Bob King, who has been
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