DFSS, Innovation and I-TRIZ Tools
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DFSS, Innovation and I-TRIZ Tools

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DFSS, Innovation and I-TRIZ Tools DFSS, Innovation and I-TRIZ Tools Presentation Transcript

  • DFSS, Innovation and I-TRIZ Tools “ Innovative Designs for Six Sigma”
  • BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINS Global Leaders in their fields                     Genrich Saulovich Altshuller Father of TRIZ Dr. Joseph M. Juran Father of Breakthrough Improvement
  • OUR CREDIBILITY AND EXPERIENCE
    • A 23-year successful Juran track record in achieving bottom-line results through pragmatic and systematic implementation of quality management and breakthrough methodologies for our clients.
    • The Juran-Ideation partnership creates from the strengths and capabilities of two industry leaders a synergistic offering of Innovation and Six Sigma Performance.
    • A proven, comprehensive business approach, “strategic and tactical” due to the depth and breadth of the full-time Juran Institute staff and services that are unsurpassed by our competitors.
    • Juran Institute DFSS training and consulting materials are experience-based, translated in multiple languages. Many of our materials are basic references which are used by clients, universities and other consultants.
    • The DFSS-TRIZ Integration is a unique offering in the industry.
  • IDEATION INTERNATIONAL INC.
    • Ideation established 1992
    • Merged with Kishinev School (Leading TRIZ School in Russia)
    • Headquarters in Southfield, MI
    • 85% of the world’s leading TRIZ Scientists
    • Installed customer base of over 2,000 enterprises worldwide
    • Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers established worldwide
  • IDEATION’S MISSION Ideation International is a world-class provider of accelerated education, innovation software tools, and analytical services based upon the Ideation/TRIZ Methodology, to enterprises of all types and sizes. By understanding the mechanisms that create change, providing the means for recognizing how to adjust to change, and bringing the essential benefits of innovation, creativity and knowledge to enterprises, Ideation will achieve its mission.
  • WHAT IS IDEATION’S BUSINESS? Inventive Problem Solving Failure Analysis Failure Prediction Anticipatory Failure Determination Education Software Publications Analytical Services Books Papers Book Papers 54 yrs 22 yrs 22 yrs 12 yrs Directed Evolution Papers Under Development Provider of I-TRIZ: Age of Application
  • JURAN INSTITUTE’S MISSION Our mission is to provide professional consulting services to improve continuously the performance of our clients’ processes, products, people, and profits .
  • JURAN INSTITUTE
    • Founded 22 years ago by Dr. J. M. Juran.
    • Leading source world-wide for research, consulting, and education in managing for Six Sigma quality to achieve superior business results.
    • Six Sigma Quality is one of our key businesses today. In the present and future, like the past, we have built on our competencies - like our competitors. One difference, the Juran Quality Model is the heart of Six Sigma.
    • High quality (high sigma values) reduces costs, increases revenues, creates loyal customers and a great culture.
    • Not all Six Sigma providers are alike. Juran Institute tries to adapt and be flexible in meeting local site requirements, as well as corporate goals.
  • WHAT ARE JURAN INSTITUTE’S SERVICES AND PRODUCTS? Breakthrough Problem Solving Training E-learning Publications Consulting Services Books Papers Books Papers N/A Strategic Deployment Papers Under Development Provider of Breakthrough Licensing Design for Six Sigma DMAIC Six Sigma Under Development
  • I- DESIGN FOR SIX SIGMA…DEFINED
    • I-DFSS –
      • 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 I-TRIZ tools for designing products (goods, information or services) and processes that generate customer value.
        • The phases are D efine, M easure, A nalyze, D esign, V erify
  • INNOVATIVE DESIGNS FOR SIX SIGMA…DEFINED I-DFSS: New Product/Service Introduction to Achieve Six Sigma Business Performance MARKET RESEARCH DESIGN PRODUCTION LOGISTICS DISTRIBUTION SERVICE SALES DMADV 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 Under- stand customer needs and specify CTQs Develop design concepts and high- level design Develop detailed design and control/test plan Test design and implement full-scale processes Initiate, scope, and plan the project DESIGN FOR SIX SIGMA DELIVERABLES TOOLS   Mgmt Leadership  Customer Research  FMEA/Errorproofing   Project   QFD   Process Simulation Management   Benchmarking   Design Scorecards Define Measure Analyze Design Verify Team Charter CTQs High-level Design Detailed Design Pilot
  • SOME OF OUR CLIENTS... Commercial Electronics South Korea based company-wide implementation of Six Sigma, including South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United Kingdom and United States.
  • SOME OF OUR CLIENTS... Satellite Manufacturer Implemented Design for Six Sigma
  • IDEATION’S SUCCESSES-TO-DATE: AUTOMOTIVE INDUSTRY
    • GM
    • Ford
    • Toyota
    • Chrysler
    • Eaton
    • Dana Corporation
    • Rockwell Int’l Automotive
    • TRW Automotive
    • ITT Automotive
    • Jaguar
    Cost reduction, warrantees, recalls, new design, patent circumvention, failure analysis, failure prediction, training
    • Break squeal
    • Brake roughness
    • Noise and vibration
    • Transmission
    • Air bag
    • Electrostatic paint
    • Tail light
    • Seat cover
    • Wind tunnel
    • Plastic fuel tank
  • IDEATION’S SUCCESSES-TO-DATE: CHEMICAL INDUSTRY
    • Dow
    • Amoco
    • Dupont
    • Conoco
    • Solutia
    • Rohm & Haas
    Cost reduction, breakthrough/discovery, manufacturing processes, safety, quality, reliability, failure analysis
    • Plastics
    • Chemical processing
    • Catalysts
    • Reactor
    • Aromatic oxidation
    • Distillation/separation
    • New material development/design
  • IDEATION’S SUCCESSES-TO-DATE: OIL INDUSTRY
    • Exxon
    • Mobil
    • Amoco
    • Shell
    Cost reduction, reliability, failure analysis, new design, training
    • Exploration
    • Method of discovery
    • Refineries
    • Post processing
      • Gas
      • Fuel oil
    • Enhanced oil recovery
    • Dual grading drilling
    • Expandable casing
    • Hydro carbon processing
      • on shore
      • off shore
    • Transportation
  • IDEATION’S SUCCESSES-TO-DATE: MEDICAL INDUSTRY
    • Johnson & Johnson
    • Cardiovascular
    • Roche
    • Bristol Myers
    • Zeneca (UK)
    New design, patent circumvention, cost reduction, failure prediction, training
    • Medical instrumentation
    • Sanitary products
    • Blister packaging of pills
  • IDEATION’S SUCCESSES-TO-DATE: ELECTRONICS/ELECTRICAL INDUSTRY
    • Honeywell
    • Motorola
    • Philips Electronics
    • Hitachi
    • ITT
    • Arteche (Spain)
    • Visteon
    • Northern Telecon (Canada)
    • Solarex
    • Helix
    • Toshiba
    • Sony
    • LG Electronics
    Cost reduction, new technologies, reliability, manufacturing processes, training
    • Cell phones
    • Microchips
    • PC boards
    • Radio
    • Headset
    • High voltage transformers
    • Power supplies
    • Navigation systems
  • IDEATION’S SUCCESSES-TO-DATE: AVIATION INDUSTRY
    • Boeing
    • Pratt & Whitney
    • Techspace Aero (Belgium)
    • Honeywell
    • Allied Signal
    • Rockwell International
    • Rolls Royce
    • McDonnel Douglas Aerospace
    • NASA
    • Hughes Aircraft
    • TRW
    • BF Goodrich
    • Litton
    Cost reduction, safety, reliability, quality, new design, failure analysis and prediction, training
    • C-17
    • F-22
    • Engines
    • Valves
    • Containment ring
  • I-DFSS DESIGN PROJECT CASE 1 CASE 2 CASE 3 Base Line Performance OK Current Product  DPMO COPQ Design Current Processes Manufacturing Distribution Service Marketing REDESIGN  Cp, Cpk COPQ  DPMO COPQ Current Product NEW PROCESS DESIGN Product Base Line Performance OK (May be of little value) New Product NEW PRODUCT AND PROCESS DESIGN No Base Line Performance CTQ’s High-level Design CTQ GAP “Base Line Performance” Design Scorecard But : No Current Product or Process Design New Processes New Processes
  • SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATION IPS DE AFD Inventive Problem Solving Anticipatory Failure Determination Directed Evolution Failure Analysis Failure Prediction Strategically Evolving Future Generations of Technologies & Systems Surgical Removal of Tough Technological Problems Invention of Failure Modes Elimination of Contradictions
  • I- DESIGN FOR SIX SIGMA
    • Pre-DEFINE Phase
      • INTRODUCTION TO SIX SIGMA
      • HOW TO THINK ABOUT DFSS/NEW PRODUCT INTRODUCTION (NPI)
      • I-TRIZ/Directed Evolution (DE)
        • Strategic vision
        • Logical chain of product concepts
        • Product evolution roadmap
    • DEFINE Phase
      • INTRODUCTION TO DEFINE
      • ESTABLISH DESIGN PROJECT
      • FINANCIAL ANALYSIS
      • PROJECT MANAGEMENT AND RISK ASSESSMENT
      • SUMMARY; ISSUES TO CONSIDER
    I- DESIGN FOR SIX SIGMA
    • MEASURE Phase
      • INTRODUCTION TO MEASURE
      • ESTABLISH CTQ’s AND CTI’s
      • I-TRIZ/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
      • I-TRIZ/Anticipatory Failure Determination (AFD)
        • Failure prediction
      • DESIGN SCORECARD
    I- DESIGN FOR SIX SIGMA
    • ANALYZE/HIGH-LEVEL DESIGN Phase
      • INTRODUCTION TO HIGH-LEVEL DESIGN
      • DEVELOP DESIGN ALTERNATIVES
      • I-TRIZ/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-VARI ANALYSIS
      • CONFIDENCE INTERVALS AND SAMPLING
      • HYPOTHESIS TESTING AND ANOVA
      • EVALUATE HIGH-LEVEL DESIGN
      • I-TRIZ/Anticipatory Failure Determination (AFD)
        • Failure analysis and prediction
    I- DESIGN FOR SIX SIGMA
    • DETAIL DESIGN Phase
      • INTRODUCTION TO DESIGN
      • RISK ASSESSMENT/FALURE ANALYSIS
      • I-TRIZ/Anticipatory Failure Determination (AFD)
        • Failure analysis
      • TAGUCHI METHODS AND ROBUST DESIGN
      • TOLERANCING
      • DOE with RSM
    I- DESIGN FOR SIX SIGMA
    • DETAIL DESIGN Phase (cont’d)
      • RELIABILITY and AVAILABILITY
      • NON-PARAMETRIC STATISTICS
      • SIMULATION with Monte Carlo Methods
      • DESIGN FOR MANUFACTURABILITY/DESIGN FOR ASSEMBLY
      • DVT/TESTABILITY
      • DESIGN SCORECARD
    I- DESIGN FOR SIX SIGMA
    • DETAIL DESIGN Phase -- CUSTOM FEATURES
      • THE TOOLS OF DETAIL DESIGN
      • CONCURRENT ENGINEERING
      • SOFTWARE ENGINEERING METHODS AND TOOLS
        • (CMM, CASE)
    I- DESIGN FOR SIX SIGMA
      • ENHANCED DESIGN FOR:
      • Commercial/Competitive Success
      • Manufacturability
      • Serviceability
      • Reliability
      • Availability
      • Information Management
      • Control
    • VERIFY Phase
      • INTRODUCTION TO VERIFY
      • DESIGN FOR CONTROL
      • DESIGN FOR MISTAKE- AND FOOLPROOFING
      • STATISTICAL PROCESS CONTROL (SPC)
      • MVT
      • TRANSITION TO PROCESS OWNERS
      • I-TRIZ/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
    I- DESIGN FOR SIX SIGMA
    • VERIFY Phase -- CUSTOM FEATURES
        • PILOT TESTING
        • FULL-SIZE SCALE-UP AND COMMERCIALIZATION
        • DESIGN INFORMATION AND DATA MANAGEMENT
        • LEAN MANUFACTURING
    I- DESIGN FOR SIX SIGMA
  • I- DESIGN FOR SIX SIGMA D-M A D V 15 - 16 Weeks Training Weeks Project 1 3 1 4 1 4 - 6 1 4 - 6 IDEAL V DR-3 D DR-2 A PP D-M DVT MVT DR-4 19 - 22 Weeks (5-6 Months)
    • Critical Success Factors:
    • Project starts with training
    • Project < 6 months
    • Project phases match training schedule
     DMADV Training/Project Map
  • I- DESIGN FOR SIX SIGMA Training Project (D) Mass Production Training (B) (C) (A) ? OK ? No Start REAL DR-2 Start DR-3 Gap Start Start Project Training Training Consulting D-M  DMADV Training/Project Map Product Planning Project Project
  • SIX SIGMA DMADV TRAINING FLOW
    • DMADV
    Executive Briefing Preparations Champion Training/Workshop Go-No go Decision Master Black Belt Program Trained Black Belt Certified Black Belt Black Belt Training Black Belt Project Master Black Belt Project Certified MBBs 2 days 4-8 hrs J URAN Sr. Instructor J URAN Sr. Instructor J URAN I NSTRUCTOR (first wave) Total Duration: 4-6 months Total Duration: 4-6 months J URAN Sr . I NSTRUCTOR Yes No ? Certification Project Define/Measure Analyze Design Verify D/M A D V Statistics, Finance Leadership Skills