Design for six_sigma

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Design for six_sigma

  1. 1. Design for Six SigmaDesign for Six Sigma Design for Six SigmaDesign for Six Sigma Prepared By :Prepared By : SHAIVYA GUPTASHAIVYA GUPTA B.Tech. EN VI semB.Tech. EN VI sem
  2. 2. Design for Six SigmaDesign for Six Sigma What is a SIGMA ?What is a SIGMA ? • A metric that indicates how well a process is performing. • Higher is better. • Measures the capability of the process to perform defect-free work. • Also known as “z”, it is based on standard deviation for continuous data. • For discrete data it is calculated from DPMO [Defects Per (one) Million Opportunities]. •Log on to www.thoughtcrackers.blogspot.com to download this ppt.
  3. 3. Design for Six SigmaDesign for Six Sigma Six SigmaSix Sigma :: Unacceptable deviation from the mean or target Accuracy & precision of a process can be best explained by using the analogy of a rifle firing at a target. Six Sigma is a methodology to manage process variations that cause defects,t; and to systematically work towards managing variation to eliminate those defects. The objective of Six Sigma is to deliver high performance, reliability, and value to the end customer. It was pioneered by Bill Smith at Motorola in 1986 and was originally defined as a metric for measuring defects and improving quality; and a methodology to reduce defect levels below 3.4 Defects Per (one) Million Opportunities. (DPMO), or another way, a methodology of controlling a process to the point of ± six sigma (standard deviations) from a centerline.
  4. 4. Design for Six SigmaDesign for Six Sigma Six SigmaSix Sigma :: methodology Six Sigma follows the methodology DMAIC Basic methodology consists of the following five phases: Define:Define: formally define the process improvement goals that are consistent with customer demands and enterprise strategy. Measure:Measure: to define measurements on current process for future comparison. Map and measure the process in question and collect required process data. Analyze:Analyze: to verify relationship and causality of factors. What is the relationship? Are there other factors that have not been considered? Improve:Improve: optimize the process based upon the analysis using techniques like Design of Experiments. Control:Control: setup pilot runs to establish process capability, transition to production and thereafter continuously measure the process and institute control mechanisms to ensure that variances are corrected before they result in defects.
  5. 5. Design for Six SigmaDesign for Six Sigma MaterialMaterial AssembliesAssemblies ComponentsComponents SuppliersSuppliers ConsumablesConsumables MeasurementMeasurement CountingCounting InstrumentsInstruments GaugingGauging TestsTests EnvironmentEnvironment Noise levelNoise level HumidityHumidity TemperatureTemperature LightingLighting MachineMachine TechnologyTechnology VariabilityVariability ToolingTooling FixturesFixtures MethodsMethods ProceduresProcedures PoliciesPolicies AccountingAccounting PeoplePeople TrainingTraining ExperienceExperience SkillSkill VariationVariation Sources of Variations and Defects :Sources of Variations and Defects :
  6. 6. Design for Six SigmaDesign for Six Sigma DFSS (Design for Six Sigma) :DFSS (Design for Six Sigma) : PreSolution to future Problems DFSS has a different objective ,that of determining the needs of customers and the business, and driving those needs into the product solution created.
  7. 7. Design for Six SigmaDesign for Six Sigma Business ChallengesBusiness Challenges Customers demand product excellence • Excellence is defined as the ideal balance of product attributes, such as Cost, Quality, Performance, Aesthetics, Packaging, etc. • Manage variability of customer-facing product attributes. • Improve the predictability and capability of the product development process. Market demands reduced costs and increased profitability •Increase product development process effectiveness. •Directly meet customer requirements. •More effectively manage product development costs.
  8. 8. Design for Six SigmaDesign for Six Sigma Design for Six Sigma follows method DMADV. Basic methodology consists of the following five phases: Define:Define: formally define the goals of the design activity that are consistent with customer demands and enterprise strategy. Measure:Measure: identify CTQs (critical to qualities), product capabilities, production process capability, risk assessment, etc. Analyze:Analyze: develop and design alternatives, create high-level design and evaluate design capability to select the best design. Design:Design: develop detail design, optimize design, and plan for design verification. This phase may require simulations. Verify:Verify: design; setup pilot runs, implement production process and handover to process owners. DFSS (Design for Six Sigma) :DFSS (Design for Six Sigma) : Methodology
  9. 9. Design for Six SigmaDesign for Six Sigma Differences between Six Sigma and DesignDifferences between Six Sigma and Design For Six SigmaFor Six Sigma Six SigmaSix Sigma Design for Six SigmaDesign for Six Sigma • DMAIC : Define, Measure, Analyze, Improve, Control • DMADV: Define, Measure, Analyze, Design Improve, Control and Verify • DMADOV: Define, Measure, Analyze, Design, Optimize, and Verify Looks at existing processes and fixes Problems. Focuses on the up-front design of the product and process More reactive More Proactive Dollar benefits obtained from Six Sigma can be quantified rather quickly. Benefits are more difficult to quantify and tend to be more long-term. It can take six to 12 months after the launch of the new product before you will obtain proper accounting on the impact.
  10. 10. Design for Six SigmaDesign for Six Sigma StartStart Does Product/serviceDoes Product/service Currently Exists?Currently Exists? OptimizeOptimize ValidateValidate DefineDefine MeasureMeasure AnalyzeAnalyze ImproveImprove Is improvementIs improvement sufficientsufficient ????/????/ IdentifyIdentify DesignDesign ControlControl Yes No YesNo DFSSDFSS TraditionalTraditional Six SigmaSix Sigma The Big Picture :The Big Picture : EndEnd
  11. 11. Design for Six SigmaDesign for Six Sigma ““You don’t know what you don’t know.”You don’t know what you don’t know.” -Mikel Harry, co-founder of the Six Sigma Academy Predicting Design BehaviorPredicting Design Behavior DFSS now looks to predict how the designs under consideration will behave. Numerous engineering and statistical methods provide the basis for prediction. DFSS provides a structured way to constructively use the information learned from such unknown events in the next program.
  12. 12. Design for Six SigmaDesign for Six Sigma Examples:Examples: Simulation and High Performance Computing (HPC) Simulation of stress and vibrations of turbinSimulation of stress and vibrations of turbin assembly for use in nuclear power generationassembly for use in nuclear power generation powerpower AutomotiveAutomotive Simulation of underhood thermal cooling for decreaseSimulation of underhood thermal cooling for decrease in engine space and increase in cabin space and comfortin engine space and increase in cabin space and comfort AerospaceAerospace ElectronicsElectronics Evaluation of dual bird-strike on aircraft engineEvaluation of dual bird-strike on aircraft engine nacelle for turbine blade containment studiesnacelle for turbine blade containment studies Evaluation of cooling air flow behaviorEvaluation of cooling air flow behavior inside a computer system chassisinside a computer system chassis
  13. 13. Design for Six SigmaDesign for Six Sigma Examples:Examples: Computer Aided Engineering (CAE) and Simulation Software Mechanical motion:Mechanical motion: Multibody kinetics and dynamicsMultibody kinetics and dynamics Implicit Finite Element Analysis:Implicit Finite Element Analysis: Linear and nonlinearLinear and nonlinear statics, dynamic responsestatics, dynamic response Explicit Finite Element Analysis :Explicit Finite Element Analysis : Impact simulation,Impact simulation, metal formingmetal forming General Computational Fluid Dynamics:General Computational Fluid Dynamics: Internal andInternal and external flow simulationexternal flow simulation
  14. 14. Design for Six SigmaDesign for Six Sigma Application and success:Application and success: Healthcare "A Six Sigma process improvement team charged with getting heart attack patients from the Emergency Department into the cardiac catheterization lab for treatment faster slashed 41 minutes off the hospital's mean time" Banking Bank of America has used Six Sigma for credit risk assessment reduction, fraud prevention, and customer satisfaction improvement, etc. Insurance Insurance companies have used Six Sigma for critical tasks like premium outstanding reduction and various cycle time reductions. For example, CIGNA Dental reports pending claim volume reduction by over 50%. Construction In engineering and construction of the Channel Tunnel Rail Link project in the UK, the Bechtel’s project team uncovered a way to save hundreds of job hours on one of the tunneling jobs. The Institute of Quality Assurance has interesting success stories on Wipro, Citibank, and Motorola. Military The United St ates Navy has adopted Six Sigma as part of AIRSpeed, an overall set of practices designed to improve efficiency in aviation maintenance. Programming JPMorgan Chase & Co. tried combining Six Sigma with the computer programming methodologies of Extreme Programming (XP), and Capability Maturity Model Integration (CMMI).
  15. 15. Design for Six SigmaDesign for Six Sigma Problems in implementing Six Sigma at these places 1. Millions of dollars in investment is required 2. Dedication of their best full time resources 3. Training of the masses
  16. 16. Design for Six SigmaDesign for Six Sigma That’s all for Now !!!That’s all for Now !!!

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