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Role of Design for Six Sigma in Total Product Development

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Role of Design for Six Sigma in Total Product Development Role of Design for Six Sigma in Total Product Development Copyright © 2006 Six Sigma Academy International, LLC All rights reserved; for use only in compliance with SSA license. Presentation Outline • Introduction to Six Sigma • DMAIC Approach • Benefits and Limitations of DMAIC • Introduction to Design For Six Sigma (DFSS) • DMAIC VS DFSS • Steps in DFSS • Case Studies • Deploying DFSS Copyright © 2006 Six Sigma Academy International, LLC Pg 1 All rights reserved; for use only in compliance with SSA license. What Is Six Sigma? • Philosophy • Vision • Initiative • Goal • Method •Tool • A means to stretch our thinking with respect to quality. Copyright © 2006 Six Sigma Academy International, LLC Pg 2 All rights reserved; for use only in compliance with SSA license. Six Sigma Is Different From Past Quality Programs In That It… • Changes business measurements • Changes the role of finance • Monitors projects to closure • Sustains the gains • Results in demonstrable success • Improves competitiveness …and is bottom line-focused and led by executives. Copyright © 2006 Six Sigma Academy International, LLC Pg 3 All rights reserved; for use only in compliance with SSA license. Six Sigma Benefits • Enables success in a world of intensified competition and declining margins • Ensures quality necessary to satisfy increasingly demanding customers • Provides means to become the best in the world • Establishes standard language and approach across all functions and lines of business • Helps develop next generation of leaders Results directly linked with business objectives. Copyright © 2006 Six Sigma Academy International, LLC Pg 4 All rights reserved; for use only in compliance with SSA license. Premise Of Six Sigma • The basic premise of Six Sigma is that sources of variation can be: - Identified - Quantified - Eliminated or controlled • Focused on strategic or core processes • Data driven - Measurements focused on right things Variation is the enemy! Copyright © 2006 Six Sigma Academy International, LLC Pg 5 All rights reserved; for use only in compliance with SSA license. Getting To Six Sigma Process Capability Defects per Million Long Term Yield OpportunitiesIt σst 2 308,537 69.15% 3 66,807 93.32% 4 6,210 99.38% 5 233 99.98% GOAL 6 3.4 99.99966% Copyright © 2006 Six Sigma Academy International, LLC Pg 6 All rights reserved; for use only in compliance with SSA license. DMAIC Approach for Problem Solving Measure Analyze Practical Problem Statistical Problem yfxx= (,12 ,...,) xk Practical Solution Statistical Solution Control Improve Copyright © 2006 Six Sigma Academy International, LLC Pg 7 All rights reserved; for use only in compliance with SSA license. Dynamics Of Execution Strategy The Funnel Effect Define Phase Measure Phase 30-50 Inputs (X) Analyze Phase 10-15 Xs 8-10 KPIVs Improve Phase 4-8 Key KPIVs Control Phase 3-6 Key KPIVs Optimized Process Copyright © 2006 Six Sigma Academy International, LLC Pg 8 All rights reserved; for use only in compliance with SSA license. 12 Steps in DMAIC Approach 1. Select Output Characteristic 2. Define Performance Standards 3. Validate Measurement System 4. Establish Baseline Process Capability 5. Define Performance Objectives 6. Identify Variation Sources 7. Screen Potential Causes 8. Discover Variable Relationships 9. Establish Operating Tolerances – Implement Improvements 10.Validate Measurement System 11.Determine Final Process Capability 12.Implement Process Controls Copyright © 2006 Six Sigma Academy International, LLC Pg 9 All rights reserved; for use only in compliance with SSA license. Limitation of DMAIC Approach The DMAIC approach can improve existing products and services to a level which they are capable of, but the overall product or service performance may be limited by design. In order to overcome this limitation, Design for Six Sigma (DFSS) approach is recommended as it covers a full range of product and service design starting with the voice of the customer (VOC) and ending with product or service launch. Copyright © 2006 Six Sigma Academy International, LLC Pg 10 All rights reserved; for use only in compliance with SSA license. The Impact of DFSS • By integrating DFSS methods and tools within their design organizations, companies have experienced the following benefits: - Shorter development cycles from idea-to-sale - Reduction is design process complexity - Reduced warranty cost after launch - Reduced early-life failures - Increase initial customer satisfaction - Greater efficiency in design resource utilization - Less post-pilot design changes - Easier integration of geographically separated design groups Pg 11 Copyright © 2001-2005 Six Sigma Academy International, LLC II. Design For Six Sigma All rights reserved; for use only in compliance with SSA license. How The Impact of DFSS Is Seen DFSS requires more resources early, but offers more effective utilization and less overall resource use during the design cycle. l e Actual v e Resource L Utilization e Budgeted c r Resource u o Utilization s Typical DFSS Traditional e Resource Post Release R Utilization Problems Design Cycle Launch Date Pg 12 Copyright © 2001-2005 Six Sigma Academy International, LLC All rights reserved; for use only in compliance with SSA license. DFSS (IDOV) Methodology • The DFSS (IDOV) process consists of eight phases which align to the following main steps: - Identify: Identify customer needs and strategic intent. - Design: Deliver the detailed design by evaluating various design alternatives. - Optimize: Optimize the design from a productivity (business requirements) and quality point of view (customer requirements), and realize it - Validate: Pilot the design, update as needed and prepare to launch the new design. Copyright © 2006 Six Sigma Academy International, LLC Pg 13 All rights reserved; for use only in compliance with SSA license. The IDOV Roadmap Identify Design Optimize Validate • Find customer • Identify Operational • Identify Inner Noise • Measurement & wants and needs Noise • Apply Noise Strategy Process Controls • Conduct Feasibility • Identify Inner Noise • Flow Down • Leverage to other Study | Assess Requirements applications • Convert Wants and Technology Needs to CTSs • Develop Transfer • Validate Business Functions • Apply Noise Case Strategy • Predict Design Capability • Optimize design and • Flow Down value Requirements • Plan test for functionality • Create Design Concepts • Conduct Test for functionality • Evaluate design • Develop control plans solutions • Build confirmation pilot • Develop Transfer • Verify process & Functions measurement • Predict Design capabilities Capability • Implement Design Pg 14 Copyright © 2001-2005 Six Sigma Academy International, LLC All rights reserved; for use only in compliance with SSA license. The Roadmap for DFSS Designs The Design For Six Sigma roadmap (IDOV) ensures design accountability Identify Design Optimize Validate Find Customer Wants & Needs Identify Operational Noise Conduct Feasibility Study / Assess Identify Internal Noise Technology (product variation) Validate Business Convert customer Case wants & needs to measurable CTS’s & values Apply Noise Strategy Flow Down & Uncouple / Decouple the Ideal Function & other Requirements Develop Transfer Functions Predict Design Capability Optimize Design and Value Develop Control Plans Build Confirmation Pilot /Prototypes Verify Process & Measurement Implement and Plan Test for Capabilities institutionalize Functional / Prototypes/ Verification Design, Measurement & Process Controls Conduct test for Functional / Leverage to Prototypes/ Other Applications Verification Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Phase 6 Phase 7 Phase 8 Customer Reqs. Conceptual Preliminary Final Product Process Launch Post - Strategic Intent Design Design Design Verification Verification Launch Phase/Gate 1 Phase/Gate 2 Phase/Gate 3 Phase/Gate 4 Phase/Gate 5 Phase/Gate 6 Phase/Gate 7 Phase/Gate 8 Pg 15 Copyright © 2001-2005 Six Sigma Academy International, LLC All rights reserved; for use only in compliance with SSA license. The Knowledge Base & Tool Set DFSS Curriculum, Tools & Methods Phase Curriculum Topics Tools & Methods Find Customer Wants and Needs Listening to the Customer Voice P1 - Customer Conduct Feasability Study Assess Technology Kano Method Requirements/ Strategic Validate Businsess Case QFD Intent Identify Operational Noise QFD Identify Inner noise SIPOC DFSS design teams Convert customer wants/needs to measurable CTS'sProcessing Mapping P2 - Conceptual Design Apply noise strategy Design Concepts Flow-down requiremnets (uncouple/decouple) Pugh apply advanced design Create design concepts TRIZ Evaluate design soutions methods and tools Design Identify Identify Inner noise Robust Design Apply noise strategy QFD Flow-down requiremnets (uncouple/decouple) Axiomatic Design Zigzag Process P3 - Preliminary Design throughout the phases of Develop transfer functions Design Scorecards Predict Design Capability Process Mapping a rigorous product, FMEA Identify Inner noise Robust Design Apply noise strategy Axiomatic Design Zigzag Process service, or process Flow-down requiremnets (uncouple/decouple) Simulations P4 - Final Design Develop transfer functions Capability analysis design roadmap to Predict design capability Lean techniques,TRIZ Optimize design and value ensures proper design Plan test for functional/prototypes/verification Apply noise strategy Robust Design Develop control plans Control Plans discipline and superior P5 - Product Verification Build confirmation pilot/prototypes SPC Plan test
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