Your SlideShare is downloading. ×
Lean Design For Six Sigma at Tyco Engineered Products & Services
Upcoming SlideShare
Loading in...5
×

Thanks for flagging this SlideShare!

Oops! An error has occurred.

×

Introducing the official SlideShare app

Stunning, full-screen experience for iPhone and Android

Text the download link to your phone

Standard text messaging rates apply

Lean Design For Six Sigma at Tyco Engineered Products & Services

1,026
views

Published on

Published in: Education, Business, Technology

0 Comments
1 Like
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total Views
1,026
On Slideshare
0
From Embeds
0
Number of Embeds
1
Actions
Shares
0
Downloads
39
Comments
0
Likes
1
Embeds 0
No embeds

Report content
Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
No notes for slide

Transcript

  • 1. Lean Design For Six Sigma at Tyco Engineered Products & Services Ajoy Basu
  • 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. 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. Why DFSS? 3  4.5  6 
  • 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. Gate 0: NPV Analysis Uncertainties fed into Analysis
  • 7. Gate 0: Technology Gap Time Performance Parameter
  • 8. Gate 1: Psychological Inertia
  • 9. Gate 2: Lean WIP = CT * TP
  • 10. Lean Analysis
  • 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. 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. 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. Gate 4: Reliability
  • 15. DFSS Rollout Plan
    • Success Factors
    • Develop integrated NPD - DFSS process
    • Close gap regarding VOC, VOM
    • Candidate selected for DFSS MBB career path
    • Select projects early in design cycle (within 6 months)
    • Diligent and rigorous toll gate reviews
    • Attentive portfolio management
  • 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. 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. Project Database
  • 19. Certification
    • 200 hrs of class room instruction
    • 80+% score in DFSS exam
    • 1 Platform level project or
    • 2 Platform extensions
    • (no $ value for DFSS projects)
  • 20. Measuring DFSS Success
    • Vitality Index
    • Profit / Engineering $
    • Say / Do ratio