Lean Six Sigma White Belt Training

1. Lean Six Sigma White Belt Training
Modul 3.4: Design for Six Sigma
https://leanbase.de/onlineacademy

2. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Design for Six Sigma – IDDOV
Identify, Define, Design, Optimize, Validate &Verify
or
DMADV – Define, Measure, Analyse, Design, Verify

3. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
What ist Design for Six Sigma?

4. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Get it the first time right!

5. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
P-Diagram of PEP – a meta view on DfSS
Noise
Product
Engineering
Process
X (Input) Y (Product)
Design
• Needs
• Requirements
• Standards
• Guidelines
• Tools & methods
• Communication
• Specifications
• Reviews & reports
• Collaboration issues
• Missalignment
• Missunderstanding

6. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Process
• Customers
• Understand and quantify customers‘ needs
and requirements
• Stakeholders
• Corporate business goals, financial goals,
business case
• History
• Evaluate historical external & internal data
to find CTQs
Tools
• Customers
– Surveys, VOC, Kano model
– Tagushi loss function
• Stakeholders
– Stakeholder map, B/C
– VOB, VOP, CTQ tree
• History
– 7 QC tools
– Capability analysis
– Regression analysis
Identify

7. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Process
• Flow-down customer, stakeholder,
gouvermental and historical critical to
satisfaction Ys down to tangible CTQs
and design Xs
Tools
• QFD
• CTQ tree
• Cause & Effect matrix
• Tagushi loss function
• Business Case
• CTQ scorecard
• Benchmarking
• Product cost matrix (yield matrix)
• Capability analysis
Define

8. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Process
• Build concepts and evaluate them to
CTQs and Xs
• Simulate and explore product
robustness to manufacturing and usage
variation
• Simulate and explore process
robustness to product and
manufacturing variation
Tools
• Pugh concept selection
• Process mapping
• Tagushi loss function
• Simulations (lead times, yield, cost etc.)
• FMEA (product, process, supply chain)
• TRIZ
• Robust engineering
• DFM, DFA, DFT
• Product cost matrix
Design

9. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
• Run experiments
• Analyze data
• Set design and process
parameters to optimize for
robustness
• DOE
• Gauge R&R
• Poka-Yoke
• Capability analysis
• ANOVA
• TRIZ
Process Tools
• Robust engineering
• DFM, DFA, DFT
• Regression analysis
• Fault trees
• Product cost matrix
• DMAIC
Optimize

10. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Process
• Validate & verify product (and process)
performance to CTQs and customer and
stakeholder requirements
• Set up appropriate product and process
control mechanisms to establish long
term quality assurance
Tools
• DOE
• Gauge R&R
• SPC
• Poka-Yoke
• Capability
analysis
• ANOVA
• P-diagram
• Regression
analysis
• Fault trees
• DMAIC
• Product cost
matrix
Validate & Verify

11. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Validate vs. Verify
=
Effectivity vs. Efficiency

12. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
Effectivity will be validated
 Have we done the right thing?
vs.
Efficiency will be verified
 Have we done it right?

13. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma
DMAIC ~ 70 % of all Six Sigma projects
DFSS ~ remaining 30 %
applicable in
engineering, production, service, etc.

14. Lean Six Sigma White Belt Training — 3.4 Design for Six Sigma