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Design for Six Sigma
Design for Six Sigma
Design for Six Sigma
Design for Six Sigma
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Design for Six Sigma


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  • 1. Design for Six Sigma Capitalizing on Product Development Improvements, Cost Reduction and Organizational Excellence Through DFSS Palmer House Hilton Chicago, IL November 18-19, 2003 80% of production costs are established during the design or engineering phase. Conference Chair: Featuring Case Studies and Presentations from: Tom Judd Mohamed A. Ali Mahesh H. Vora Cognition Corporation General Electric Ford Motor Company VP, Six Sigma Solutions Master Black Belt Senior Staff Technical Specialist Manager Adi Choudri Jeffrey Hines The Following Key Issues will be Addressed Gencorp Aerojet Smith & Nephew, Inc. at the Conference: Master Black Belt, Engineering Champion, Master Black Belt, • Examine how design for six sigma strategies Lean and Six Sigma Operational Excellence Program Office differ from core six sigma programs with Ford Parveen Goel Ian Osborn • Discover how Maytag improved their measurement TRW Steering & Suspension Engineering Maytag systems for DFSS through incorporating Global Chief Engineer, Six Sigma and Reliability Manager built-in methodologies Michael A. Carver Design and LeanSigma • Understand how Union Pacific maintains Union Pacific Steven C. Sanders, Ph.D. a customer focus by integrating the customer Director, Six Sigma, Certified Master Black Belt Storage Technology Corporation in the design process Bill Russell Business Management Officer, • Benchmark Gencorp Aerojet's application of lean Raytheon Engineering Excellence Program product development tools to build a product Six Sigma Institute capability database for DFSS Mark E. Nall Collin Reeves NASA • Determine the impact of measurement system Raytheon Director, Space Product Development Group error and its effect on performance and cost Supplier Technical Consultant with Raytheon Dana Crowe Mike Mladjenovic • Ascertain how to use DFSS tools to redesign Tyco Electronics Intier Automotive Interiors Ontegra Etobicoke for the next generation, with Freudenberg NOK Master Black Belt Assistant General Manager and Former Director, Manager Operational Excellence • Learn from GE how to embrace long-term Six Sigma and Continuous Improvement DFSS strategies to ensure prosperity as your Scott P. Baird John Limperis program matures ProcessModel, Inc. NASA Food Technology Commercial Space Center • NASA explores how to improve your product President and CEO Director, Outreach Space Product Development development process through research James Stana Roxanne O'Brasky partnerships and space-based research Lockheed Martin Missiles and Fire Control International Society of Six Sigma Professionals (ISSSP) Coordinator of DFSS President Collaborative Sponsors: Recommended Professional Organization: Media Partners: Recommended Six Sigma Resource
  • 2. Day One | November 18, 2003 8:00 Registration and Coffee 12:30 Lunch and Networking Time 8:45 Chairperson's Opening Remarks 1:30 Case Study Tom Judd Achieving Outstanding Six Sigma Process Design Cognition Corporation • Test planned or projected processes against performance metrics VP, Six Sigma Solutions • See accurate financial tradeoffs for selected design options 9:00 Case Study • Visually observe potential process problems prior to investment Examining How Design for Six Sigma Strategies • Automatically prioritize greatest process problem/potential reward Differ from Core Six Sigma Programs • Use automatic 'optimization' to develop best processes • Comparing general six sigma DMAIC applications with the DFSS Scott P. Baird paradigm in product development ProcessModel, Inc. • Leveraging computer automated design systems and supporting President and CEO infrastructure to streamline the process • Applying the axes with the most economical results for optimal ROI 2:15 Case Study • Integrating your DFSS implementation with your manufacturing The Financial Impact of an 'Unwanted Partner' six sigma program • Examining the impact of measurement system error and its effect Mahesh H. Vora on performance and cost Ford Motor Company • Incorporating lessons learned into the design process Senior Staff Technical Specialist Manager • Improving design in the light of production tests and manufacturing systems 9:45 Case Study • Minimizing the associated Cost of Poor Quality (COPQ) Meeting the Challenges of Transitioning from Six Sigma and increasing revenue to Design for Six Sigma Bill Russell • Vision, commitment and resources Raytheon • Cornerstones of design for six sigma architecture Six Sigma Institute • Design for six sigma knowledge management Collin Reeves • Evolving from a static to a dynamic mode Raytheon Mike Mladjenovic Supplier Technical Consultant Intier Automotive Interiors Ontegra Etobicoke Assistant General Manager and Former Director, 3:00 Coffee and Networking Time Six Sigma and Continuous Improvement 3:30 Case Study 10:30 Coffee and Networking Time Design For Six Sigma: 'Designing in Robustness': 11:00 Case Study How to Design for Reliability in the DFSS Cycle Embedding DFSS Tools and Methods in a Systems Engineering from 'Voice of the Customer' Through Sustaining Production Process for Maximum Effectiveness • Meeting cost-down challenges while increasing value • Establishing a systems engineering process and structure • Applying the right tools for efficient product development • Aligning DFSS tools and methods within a systems engineering process • Jumping over the 'design wall' • Involving the right people in the process • Evaluating the cost of business as usual • Providing support to ensure success Dana Crowe Steven C. Sanders, Ph.D. Tyco Electronics Storage Technology Corporation Master Black Belt Business Management Officer, Engineering Excellence Program Manager Operational Excellence 11:45 Case Study 4:15 Round Table Selecting the Project and Leveraging Your Successes to Achieve Successfully Dealing with Culture Change Issues Buy-In at the Product Development Level at the Engineering Level: Creating a 'Pull' vs. 'Push' Effect • Leveraging manufacturing six sigma successes This session will provide an opportunity for delegates to discuss key culture with your design department change issues with industry experts in an open forum. Audience interaction • Identifying optimal projects – setting yourself up for success is encouraged and there will be plenty of time allotted for questions. • Expanding the program and incorporating this into your Mohamed A. Ali engineering process General Electric • Attaining investment and decision making autonomy to leverage Master Black Belt future successes Adi Choudri James Stana Gencorp Aerojet Lockheed Martin Missiles and Fire Control Master Black Belt, Engineering Champion, Lean and Six Sigma Coordinator of DFSS Jeffrey Hines Smith & Nephew, Inc. Master Black Belt, Operational Excellence Program Office Business Opportunities A limited amount of exhibition space is available Mahesh H. Vora at the conference. Sponsorship opportunities covering luncheon, Ford Motor Company evening functions and documentation also exist. For further details, Senior Staff Technical Specialist Manager contact Rebecca Nicholson at 416 955 0375 ext. 207. Ian Osborn Maytag Manager, Design and LeanSigma
  • 3. Parveen Goel 11:45 Case Study TRW Steering & Suspension Engineering Leveraging Your Design for Six Sigma Strategy with Lean Tools Global Chief Engineer, Six Sigma and Reliability for Optimal Results Mike Mladjenovic • Leveraging your lean, six sigma integration successes in manufacturing Intier Automotive Interiors Ontegra Etobicoke • Evaluating and prioritizing projects for suitability and viability Assistant General Manager and Former Director, • Choosing the right lean, DFSS mix for the venture • Achieving continuity through a seamless program integration Six Sigma and Continuous Improvement Jeffrey Hines Steven C. Sanders, Ph.D. Smith & Nephew, Inc. Storage Technology Corporation Master Black Belt, Operational Excellence Program Office Business Management Officer, Engineering Excellence Program Mark E. Nall 12:30 Lunch and Networking Time NASA Director, Space Product Development Group 1:30 Case Study Ensuring Customer Focus by Integrating the Customer 5:15 Chairperson's Closing Remarks in the Design Process • Creating partnerships with the customer • Reviewing the advantages of having the customer on your design team 5:30 End of Day One vs. using traditional voice-of-the-customer tools • Mitigating the risk to new product development introduction • Expanding from the single customer to a marketplace solution Michael A. Carver Union Pacific Director, Six Sigma, Certified Master Black Belt Day Two | November 19, 2003 2:15 Case Study Embracing Long Term DFSS Strategies to Ensure Prosperity 8:15 Registration and Coffee as the Program Matures • Benchmarking and mirroring industry leader initiatives • Overcoming the roadblocks on the path to project maturity 8:45 Chairperson's Opening Remarks • Capitalizing on project successes to further extend the scope Tom Judd of the program Cognition Corporation • Developing the program beyond year two VP, Six Sigma Solutions Mohamed A. Ali General Electric 9:00 Case Study Master Black Belt Utilizing Robust Engineering Tools to Reduce Variation and Accelerate the New Product Introduction Process 3:00 Coffee and Networking Time • Separating the tools from the process 3:30 Case Study • Identify, design, optimize and validate – choosing the tools Improving the Product Development Process Through Research • Standardizing the process without restricting innovation Partnerships and Space-Based Research • Reducing engineering timelines for improved efficiency • Forming partnerships to increase research capabilities Parveen Goel and joint funding opportunities TRW Steering & Suspension Engineering • Using the benefits of space to accelerate progress Global Chief Engineer, Six Sigma and Reliability • Combining the advantages of space and innovative partnerships to create new directions for product development 9:45 Case Study Mark E. Nall NASA Incorporating Built-In Methodologies to Improve Director, Space Product Development Group Measurement Systems for DFSS • Setting up a system to identify problem areas John Limperis • Relying on and utilizing the generated mathematical data NASA Food Technology Commercial Space Center • Bringing your entire team onboard with the methodology Director, Outreach Space Product Development • Building in flexibility to evolve the process for future development 4:15 Case Study Ian Osborn How to Recognize Best Practices and Leverage Experiences Maytag The ability to measure performance according to specified standards Manager, Design and LeanSigma for comparison is vital to improving any organization's processes. The opportunity for 'branding' plays a tremendous role in Six Sigma's future 10:30 Coffee and Networking Time growth and adoption. Organizations must commit themselves to bringing a commonality to the many perspectives, the diversity of languages, which currently permeate the wealth of information available on 11:00 Case Study the practice. Through the experience of sharing and learning via networking Applying Lean Product Development Tools to Build and development programs; knowledge networks and reference sources; a Product Capability Database for DFSS and passionate support of the global community, organizations can be • Choosing your targeted projects entitled to more powerful processes and better results. • Seamlessly integrating the lean and six sigma tools and concepts Roxanne O'Brasky • Building and maintaining your database International Society of Six Sigma Professionals (ISSSP) • Establishing a structure in the sequence for future product development President Adi Choudri 5:00 Chairperson's Closing Remarks Gencorp Aerojet Master Black Belt, Engineering Champion, Lean and Six Sigma 5:15 End of Conference
  • 4. Collaborative Sponsors Recommended Professional Organization The International Society of Six Sigma Professionals (ISSSP) is committed to promoting the adoption, advancement and integration of Six Sigma How do Six Sigma teams gain more confidencein DFSS? Using in business. Join the ISSSP community of individual, corporate, affiliate ProcessModelTM, you will be able to see and test your processes ahead and partner organizations supporting this mission through advocacy and of time, test the metrics as if it is a real system and confidently assure that awareness efforts, professional recognition and development and by serving the design meets the customer needs and falls within six sigma expectations. as an information and referral source. Visit their website to become a member. Celerant Consulting provides operational strategy and implementation Media Partners services to help organizations progress rapidly from thinking differently to behaving differently. Celerant has a 16-year track record and an established presence throughout Europe and North America. The majority of its clients are top companies across energy, process, manufacturing, FMCG, financial services and infrastructure industries. Cognition supplies world-class solutions to support the implementation of the DFSS Process within the Product Development Process. Cognition provides infrastructure software solutions and subject matter expertise consulting to capture the essence of DFSS; optimize product performance while containing product development costs with the goal to maximize profit margins and meet customer needs. 2 Need E=MC ? Today's Existence in business is dependent on More Customers and Cash. Our DFSS and beyond Six Sigma approach is described in our APICS/ASQ recommended book, Implementing Six Sigma. We bring these methods to life and personalize them for you through our workshops and expert coaching. We provide Integrated Enterprise Excellence through our Smarter Six Sigma Solutions. Why You Should Attend Traditional six sigma is well understood and generally implemented throughout the manufacturing industry, but this is not the case for design for six sigma. A growing number of companies have implemented DFFS but often in an inconsistent manner on a project-by-project basis; few companies have succeeded in implementing an advanced DFFS program in their design and product development department. Developing and launching The resources you need to successfully implement Six Sigma: iSixSigma new products is a costly and risky activity and only a small number of new is the industry leading information portal and marketplace at the products end up being successful. The main benefits of a successful DFFS cutting-edge of the quality and management professions and is frequented program are significantly improved quality levels when products are launched by more than 70% of the Fortune 100 companies in America. Heralded into manufacturing and superior customer satisfaction with the end product. as 'head and shoulders above all other Six Sigma-related sites', The approach of six sigma can be comparatively characterized as a reactive iSixSigma services over 340,000 worldwide visitors per month and has quality strategy based on efficient statistical methods for defect removal won numerous awards and distinctions for providing original and and optimization. The traditional six sigma approach looks to fix what's broken, insightful articles, tools and templates, online coaching, professional in a pre-existing system. DFSS requires upfront defect avoidance because development opportunities, and many other free Six Sigma resources. the product does not yet exist. It is recognized that the later in the product cycle the defects are discovered, the higher the cost to correct them. The need for predictive ability is an integral part of any DFSS approach as understood from the perspective of the research and design of products. The challenge facing manufacturers is to realize the majority of the defect levels and quality issues during the design phase of a product and rectify these early on. filters content from over 250 respected organizations and publications worldwide. Register for free video Who Should Attend Manufacturing companies who are planning to, or are webcasts and newsletters, or review insightful white papers and scan in the process of implementing Design for Six Sigma programs. VP's and Directors the extensive library of articles. Learn how other successful of: DFSS, Engineering and R&D, Quality Standards and Business Excellency, organizations have conquered business pain and leveraged thought Corporate Quality, Six Sigma and Black Belts, Process or Business Excellence leader insights by visiting their website. and Continuous Improvement.