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Lean Design For Six Sigma at Tyco Engineered Products & Services Ajoy Basu
Engineered Products & Services $40 Billion 220,000 Employees Healthcare Electronics Fire & Security Plastics & Adhesives F...
A Holistic Approach Eliminate Waste Reduce Variation Lean Six Sigma Lean Six Sigma New Products – DFSS + ??? Product Exten...
Why DFSS? 3  4.5  6 
New Product Development Process 0 New Ideas Preliminary Investigation Preliminary Design Final Design Launch 1 2 3 4 LDFSS...
Gate 0: NPV Analysis Uncertainties fed into Analysis
Gate 0: Technology Gap Time Performance Parameter
Gate 1: Psychological Inertia
Gate 2: Lean WIP = CT * TP
Lean Analysis
Gate 3: Scorecards Customer Wants Design Features House of Quality Design Features Parts Characteristics House of Product ...
Critical Parameter Management Performance Scorecard Process Scorecard Lean Scorecard System  Scorecard Software Scorecard ...
CPM in Practice Parts Scorecard 4.50 4.90 Part D 2.40 4.72 Part E 1.93 3.02 3.46 Cumulative 2.51 2.80 3.51 Part C 6.18 3.1...
Gate 4: Reliability
DFSS Rollout Plan <ul><li>Success Factors </li></ul><ul><li>Develop integrated NPD - DFSS process </li></ul><ul><li>Close ...
DFSS Roadmap - A DEFINE D1 Needs analysis Market & Portfolio analysis, technology forecasting D2 Feasibility analysis Tech...
DFSS Roadmap - B OPTIMIZE O1 Identify Significant Xs MSA, DFMEA, C&E, Hypothesis testing O2 Develop transfer functions DOE...
Project Database
Certification <ul><li>200 hrs of class room instruction </li></ul><ul><li>80+% score in DFSS exam </li></ul><ul><li>1 Plat...
Measuring DFSS Success <ul><li>Vitality Index </li></ul><ul><li>Profit / Engineering $ </li></ul><ul><li>Say / Do ratio </...
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Lean Design For Six Sigma at Tyco Engineered Products & Services

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Transcript of "Lean Design For Six Sigma at Tyco Engineered Products & Services"

  1. 1. Lean Design For Six Sigma at Tyco Engineered Products & Services Ajoy Basu
  2. 2. Engineered Products & Services $40 Billion 220,000 Employees Healthcare Electronics Fire & Security Plastics & Adhesives Flow Control Fire & Building Electrical & Metal Thermal Controls Infrastructure & Services
  3. 3. A Holistic Approach Eliminate Waste Reduce Variation Lean Six Sigma Lean Six Sigma New Products – DFSS + ??? Product Extension – VOC + DFSS Innovate & Grow DFSS Top Line Bottom Line
  4. 4. Why DFSS? 3  4.5  6 
  5. 5. New Product Development Process 0 New Ideas Preliminary Investigation Preliminary Design Final Design Launch 1 2 3 4 LDFSS Concept Design Optimize Verify Technology Development
  6. 6. Gate 0: NPV Analysis Uncertainties fed into Analysis
  7. 7. Gate 0: Technology Gap Time Performance Parameter
  8. 8. Gate 1: Psychological Inertia
  9. 9. Gate 2: Lean WIP = CT * TP
  10. 10. Lean Analysis
  11. 11. Gate 3: Scorecards Customer Wants Design Features House of Quality Design Features Parts Characteristics House of Product Design Parts Characteristics Process Operations House of Process Planning Process Operations Process Parameters House of Production Planning PERFORMANCE SCORECARD PARTS SCORECARD PROCESS SCORECARD
  12. 12. Critical Parameter Management Performance Scorecard Process Scorecard Lean Scorecard System Scorecard Software Scorecard Parts Scorecard Robustness to manufacturing variation? Manufacturing capability of design? Quality level of components? Software Quality? Reliability Scorecard Design Reliability?
  13. 13. CPM in Practice Parts Scorecard 4.50 4.90 Part D 2.40 4.72 Part E 1.93 3.02 3.46 Cumulative 2.51 2.80 3.51 Part C 6.18 3.13 Part B 0.53 3.24 Part A Reliability Process Performance Component
  14. 14. Gate 4: Reliability
  15. 15. DFSS Rollout Plan <ul><li>Success Factors </li></ul><ul><li>Develop integrated NPD - DFSS process </li></ul><ul><li>Close gap regarding VOC, VOM </li></ul><ul><li>Candidate selected for DFSS MBB career path </li></ul><ul><li>Select projects early in design cycle (within 6 months) </li></ul><ul><li>Diligent and rigorous toll gate reviews </li></ul><ul><li>Attentive portfolio management </li></ul>
  16. 16. DFSS Roadmap - A DEFINE D1 Needs analysis Market & Portfolio analysis, technology forecasting D2 Feasibility analysis Technical feasibility & financial viability analysis CONCEPT C1 VOC KJ image, QFD, Performance Scorecard C2 Concept generation & selection TRIZ, Pugh C3 Project charter DESIGN D1 Platform Architecture / Modular design D2 Lean process analysis VSM, Takt time, Cycle time analysis D3 DFM / A Lean scorecard ( Boothroyd-Dewhurst) D4 Design scorecard Sub System Scorecard
  17. 17. DFSS Roadmap - B OPTIMIZE O1 Identify Significant Xs MSA, DFMEA, C&E, Hypothesis testing O2 Develop transfer functions DOE, RSM, robust Design, Y = f(x) O3 Design optimization Simulation, Minimize complexity, Maximize Robustness VERIFY V1 Prototype / Pilot Verify Capability V2 Reliability Analysis V3 Launch Control plans
  18. 18. Project Database
  19. 19. Certification <ul><li>200 hrs of class room instruction </li></ul><ul><li>80+% score in DFSS exam </li></ul><ul><li>1 Platform level project or </li></ul><ul><li>2 Platform extensions </li></ul><ul><li>(no $ value for DFSS projects) </li></ul>
  20. 20. Measuring DFSS Success <ul><li>Vitality Index </li></ul><ul><li>Profit / Engineering $ </li></ul><ul><li>Say / Do ratio </li></ul>
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