This presentation is the Part-I of the Product Development Manager’s Reference Guide: 6-Sigma DFSS Project Life Cycle framework for Defect Free Product Development.

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Product Development Manager’s Guide
6-Sigma DFSS Project Life Cycle
framework
for
Defect Free Product Development
Raman K.
rkattri@rediffmail.com
April 2009

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Topics
 Part-I: Six-Sigma Principles (FREE!!!)
 Part-II: Six-Sigma DFSS Methodology
 Part-III: Six-Sigma DFSS Project Life Cycle (PLC)
 Part-IV: DFSS PLC Framework for product development

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PART-I
Six Sigma Principles

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What is Sigma σ?
 The history of Six-sigma has its roots back in Gaussian Curve introduced by
Gause. He floated the concept that in any process, most of the results are
generally clustered around a particular average value. He was of opinion that
quality of the process is directly related with the shape of the Gaussian curve.
 Standard deviation is called “mean of the mean”. Used as criteria to
understand how many items possess a particular characteristics near the
mean of all the items.
 Example: Marks of students vs number of students. There will be a mean value
of marks obtained by total number of students.
Mean = Total Marks of all / number of students
 Calculate the difference in actual intake from mean.
Difference = actual marks of a student- mean marks.
 It can be positive or negative value. σ measure of the degree of dispersion of
the data from the mean value.

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What is Sigma σ?.....
 Plot the number of students possessing that difference value.
 A data point is plotted at “0” with students obtaining marks
exactly equal to mean value.
 Students obtaining marks much less than mean value will be on
left end.
 So a distribution curve is plotted showing how many students
obtain particular difference of actual marks from the mean is
plotted.
 The shape determines how many students deviates from mean
value. Narrow shape means, deviation is less, flat shape means
deviation is large.
 A mathematical quantity is calculated named Sigma.
σ = (Diff1)2
+ (diff2)2
+……+ (diffn)2
N-1

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What is Sigma σ?.....
• 1-σ: One standard deviation away from the mean in either direction on the
horizontal axis (the blue area on the graph) accounts for somewhere around
68 percent of the people in this group.
• 2-σ: Two standard deviations away from the mean (the blue and brown areas)
account for roughly 95 percent of the people.
• 3-σ: Three standard deviations (the blue, brown, green areas) account for
about 99 percent of the people.
• 6-σ: Six Standard deviation (blue, brown, green, grey areas) account for
99.99% of people.

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Sigma σ as measure of performance?
• To measure performance some specified limits of minimum and
maximum criteria of acceptable performance is to be defined.
• If marks are the output, for passing, Minimum marks required is
say 30 which becomes LSL and maximum marks can be 100
which become USL.
• According to Gaussian, there will be large number of
percentage of students who score marks near mean. There will
be only few who are have just passed marginally (Left end of
the curve) and very few who have score near to maximum
marks (Right end of the curve)
• So there are three criteria of measurement of the Performance:
• Position of Mean (Toward centre, right or left?)
• Shape of the curve (Narrow or broad?)
• Expansion of curve (always within LSL & USL or outside?)
• If all the students in the class has passed, surely the curve will
exactly fit into LSL and USL and performance is called 6-sigma.
• If 1 % of the students get failed, performance of the school
remains less than 4-sigma.
LSL USL

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Sigma σ in terms of customer satisfaction?
 In last example if we replace people with number of specifications and
variation of specifications of produced product from mean value, we will get
a distribution showing how many specifications are outside customer
specified limits.
 If a product has to fully satisfy all the customer requirements, then there
should not be any specifications falling outside 6-sigma dispersion from
mean.
 In that case product is exactly (almost 100%) as per the desire of the
customer. Then we say we have achieved 6-sigma performance and
customer satisfaction.
 There is a 6-σ deviation means 99.99% of the requirements are met.
 Same thing can be applied to manufacturing process or design. If the
perfect ness of product produced is to be almost 100% it has to be within 6-
sigma curve. Hence indicate no defect. Lesser the sigma level achieved,
more will be the defects in the product/service/process

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Relationship between defects and σ-level?
 Coined by Bill Smith of Motorola, when they found that traditionally
calculating defects per thousands in manufacturing was not the enough.
They evolved the concept of DPM and setup a method to measure and
produce quality using extensive statistical methods.
 Process capability is calculated using extensive statistical tools
 Process capability in terms of σ is a symbol of quality for customer.

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Sigma-Level as mark of Quality
 A process which can achieve quality of products in such a way that total
numbers of defects are not more than 3.4 per million, is termed as Six-Sigma
Process.
 What is Quality Product from customer point of view?
 Defect Free
 As per expectations
 Reliable
 Defects and hence the poor quality has overall effect on the customers as
well as business.
Higher
Costs
Reduced
Sales
Product
Variation
Poor
Quality
Unhappy
Customers

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6-σ Process Capability/performance
LSL USL
σ6
LSLUSL
Cp
−
=
σ
µ
3
LSL−
σ
µ
3
−USL=pkC Lesser of or

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VOC and VOP Matching
 It is not just enough to achieve 6-σ process capability (i.e. just 6-σ dispersion
around mean) but also to ensure that overall process is within customer
specified tolerance. So VOC must be contained within VOP.
Voice of Process
Performance Margins
that Always Meets
Customer Expectations
6 Sigma
Process
Capability
Low Variation in
Parts, Materials, &
Cycle Time
Acceptable
LSL USL
Voice of Customer
6 Sigma
Process
•Process operates inside the
customer requirements
•Defect free and no variation “pass
thru” to the customer
~

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Bottom Lines of 6-σ Process
 Totally customer oriented disposition which:
 Deliver Defect Free product / service or process to customer
 Product exactly or better than customer’s needs and expectations
 Reduce process cost of achieving this capability repeatedly
 6-σ integrate process, tools, methods and team together to achieve the
specified performance.

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How to achieve 6-σ capability?
 Toolset - Using a set of 6-σ Tool set (mathematical & statistical) to ensure
previously mentioned 3 objectives. Usually contains set of software tools.
 Methodology - A defined time and action frame to apply these tools. Usually
referred by different names such as DMAIC, DFSS etc.
 Process - A Organization level integrated framework to implement it, usually
called PLC, may have some proprietary names.

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6-σ Toolset
 What these tools do? – Perform some actions to reduce defects, detecting
errors, matching VOC and VOP, defining proper design and process
parameters, mapping customer and design requirements, mistake proofing
the designs and calculating process capability, etc. to achieve 6-σ
performance.
 Types of tools – A range of spread sheets, Calculations, Statistical models
and software which operate on underlying statistical theory of 6-σ

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6-σ Methodology
 What is methodology? – An approach to apply 6-σ tools at proper time to keep
the defects out of tolerance limits and confirming customer requirements
match the design requirements or not while a product is being improved upon
or being designed altogether new.
 Types of methodologies – A wide range of terminologies are used for such
methodologies:
 DMAIC (Define, Measure, Analyze, Improve, Control)
 DMADV (Define, Measure, Analyze, Design, Validate)
 DMADOV (Define, Measure, Analyze, Design, Optimize, validate)
 DCCDI (Define, Customer, Concept, Design, Implement)
 DMEDI (Define, Measure, Explore, Develop, Implement)
 IDOV (Identify, Design, Optimize, validate)

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6-σ Process
 What is Process? – Process is a structured framework provided by an
organization so that it can ensure that SUITABLE 6-Σ TOOLS are being applied
TIMELY and the output of these tools is being VERIFIED to make any
correction if needed.
 This process is propitiatory and specific to the organization itself and is
evolved after checking needs of the organization vs needs of its customers.
 6-Sigma DFSS PLC - It may be named anything in any organization. For
general reference, the process of implementing 6-σ quality in product
development is called 6-Sigma DFSS PLC (Project Life Cycle)

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Next parts of this training package
Contact the author for next set of parts as a single training
package, contact the author or purchase the same from
www.brainshark.com
Six Sigma PLC Reference Guide for Managers
 Part-II: Six-Sigma DFSS Methodology
 Part-III: Six-Sigma DFSS Project Life Cycle (PLC)
 Part-IV: DFSS PLC Framework for product development

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Author’s contact
For any questions or training queries, contact the author:
Raman K.
rkattri@rediffmail.com
Author has over 15 years of project management, product development and quality management experience
in leading MNC product development corporations. He has earned numerous international certification
awards - Certified Management Consultant (MSI USA/ MRA USA), Certified Six Sigma Green Belt
Professional (Six Sigma India), Certified Quality Director (ACI USA), Certified Engineering Manager (SME
USA), Certified Project Director (IAPPM USA), to name a few. His research and training interests are in
learning, development, performance management, research management and product development. He holds
MBA, Executive MBA, Masters in Technology and Bachelor in Technology. In addition to this, he has 60+
educational qualifications, credentials and certifications in his name.
.