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Design For Six Sigma


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DFSS - Concept & Process

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Design For Six Sigma

  1. 1. DFSS (Design for Six Sigma) Concept & Process Anand Subramaniam
  2. 2. <ul><li>“Winning isn't everything, but wanting to win is.&quot; </li></ul><ul><ul><li>- Vince Lombardi </li></ul></ul>
  3. 3. Highlights <ul><li>DFSS – Concepts & Benefits </li></ul><ul><li>DFSS – Process </li></ul>
  4. 4. DFSS – Concepts & Benefits
  5. 5. Six Sigma Methodologies Six Sigma DFSS DMAIC Process Management Improve existing processes so that their outputs meet customer requirements Control and manage cross-function processes to meet business goals Design new products & processes that meet customer needs
  6. 6. Design for Six Sigma (DFSS) - Features <ul><li>Built on Six Sigma Principles </li></ul><ul><li>High-level architectural view of the design </li></ul><ul><li>Uses statistical modeling and simulation approaches </li></ul><ul><li>Use of CTQs with well-defined technical requirements </li></ul><ul><li>Adds new tools like Quality Functional Deployment (QFD) </li></ul><ul><li>Suitable for the design of Products, Processes or services alike </li></ul><ul><li>Utilises Analysis Methods </li></ul><ul><ul><li>Predicting defects, </li></ul></ul><ul><ul><li>Avoiding defects, </li></ul></ul><ul><ul><li>Performance prediction </li></ul></ul><ul><li>Focuses is heavy on Solution Refinement via </li></ul><ul><ul><li>Failure Mode Effects Analysis (FMEA) </li></ul></ul><ul><ul><li>Design Of Experiment (DOE) </li></ul></ul><ul><ul><li>Simulations </li></ul></ul><ul><ul><li>Variation analysis of subsystems and components </li></ul></ul>
  7. 7. DFSS - Principles <ul><li>Make it right the first time </li></ul><ul><li>Develop robust solutions </li></ul><ul><li>Commitment to excellence </li></ul><ul><li>Spend resources where it counts the most </li></ul><ul><li>Ensure capability to meet customers needs </li></ul><ul><li>Must provide value in the eye of the customer </li></ul><ul><li>Concentrate on communication within the team and with the customer </li></ul>
  8. 8. DFSS - Benefits <ul><li>Clear design strategy </li></ul><ul><li>Clearly defined project criteria </li></ul><ul><li>Project focused on the Customer </li></ul><ul><li>Issues are debugged prior to implementation </li></ul><ul><li>Strong co-ordination amongst team members </li></ul><ul><li>Team buy-in to the vision & operates cohesively </li></ul><ul><li>Lower overall cost of implementation / operation </li></ul>
  9. 9. DFSS – Roll Out <ul><li>Decide if increment improvement or large scale change is needed. </li></ul><ul><li>Identify Critical Customer Requirements through the Voice of the Customer </li></ul><ul><li>DFSS requires 15% ~25%+, more resources during the Define phase </li></ul>
  10. 10. DFSS – Process
  11. 11. DFSS Methodologies IDOV Used for designing a completely new product or business process to meet customer needs and specifications or to achieve  Six Sigma quality levels Identify Design Optimise Verify DMADV An improvement system used to develop new processes or products at Six Sigma quality levels Define Measure Analyse Design Verify
  12. 12. DMADV - Define <ul><li>Identify project scope </li></ul><ul><li>Build a sense of direction </li></ul><ul><li>Understand the customers needs </li></ul><ul><li>Identify preliminary project time line </li></ul><ul><li>Identify critical customer requirements </li></ul><ul><li>Gain consensus on goals and outcomes </li></ul><ul><li>Create a vision of what success is </li></ul><ul><li>End result, a design document which serves as a guiding reference for the remainder of the project </li></ul>
  13. 13. DMADV - Measure <ul><li>Establish tolerances </li></ul><ul><li>Determine budgeting </li></ul><ul><li>Develop future measures of success </li></ul><ul><li>Product design - Select crucial features and determine how to measure them </li></ul><ul><li>Process design – identifying potential errors and how to prevent them </li></ul>
  14. 14. DMADV - Analyse <ul><li>Challenge assumptions & paradigms </li></ul><ul><li>Narrow to small list of concept proposals </li></ul><ul><li>Criteria matrix / Weighted Criteria matrix </li></ul><ul><li>Identify concepts for the new product or process </li></ul><ul><li>Identify how each step in the process contributes to the overall performance </li></ul>
  15. 15. DMADV - Design <ul><li>Selects best of the best </li></ul><ul><li>Details design alternatives </li></ul><ul><li>Focus on testing and retesting </li></ul><ul><li>Ideas - simulated, tested as prototypes and optimised to produce the best option </li></ul><ul><li>Ideas defined in sufficient details and evaluated in terms of : </li></ul><ul><ul><li>Bench Marking </li></ul></ul><ul><ul><li>Predicted Capability </li></ul></ul><ul><ul><li>Process Mapping Analysis </li></ul></ul><ul><ul><li>Process Variation Analysis </li></ul></ul><ul><ul><li>Impact on Customer Requirements </li></ul></ul><ul><ul><li>Simulations – Design of Experiment </li></ul></ul><ul><ul><li>Failure Mode & Effects Analysis (FMEA) </li></ul></ul><ul><ul><li>Brainstorming & playing Devil’s Advocate </li></ul></ul>
  16. 16. DMADV - Validate <ul><li>Testing & deployment </li></ul><ul><li>Similar to DMAIC Control phase </li></ul><ul><li>Prior to implementation, ensure following in place </li></ul><ul><ul><li>necessary documentation </li></ul></ul><ul><ul><li>monitoring systems </li></ul></ul><ul><ul><li>response plans </li></ul></ul>
  17. 17. <ul><li>“Keep away from people who try to belittle your ambitions. Small people always do that, but the really great make you feel that you, too, can become great.&quot; </li></ul><ul><ul><li>- Mark Twain </li></ul></ul>
  18. 18. <ul><li>Good Luck </li></ul><ul><li> </li></ul>