Basic concept about DFSS.product process 14 steps,and different types of tools

1. DFSS
Under the guidance, Chaitanya Chenna
Mr.Atul Patil sir. Start Date :18-6-2017
End Date : 5-7-2017

3.  Design for Six Sigma (DFSS) is a business-process management method related to
traditional Six Sigma. It is used in many industries, like finance, marketing, basic engineering,
process industries, waste management, and electronics.
 DFSS has the objective of determining the needs of customers and the business, and driving
those needs into the product solution is created.
Establishing a sustainable innovation culture
Helps to introduce something new idea, method or device.
In process design innovation could be defined through achieving breakthrough performance
25-30% increase in productivity
Innovation changes the game.

4. What is DFSS and DMAIC?

5. DEFINE
MEASURE
ANALYZE
DESIGNOPTIMIZE
VERIFY
VALIDATION
DFSS
DFSS cycle process:

6. Design
• Build System
& Sub-
System
Models
• Generate
Transfer
Functions
• Statistical
Analysis of
Variance
Drivers
• Process
Capability
Flow-up for
All
Subsystems
Optimize
• Optimize
Design
• Robust
Design
• Error Proofing
• Generate
Purchasing &
Manufacturin
g Specs
Measure
• CTQ
Flowdown to
Subsystems
&
Components
• Measurement
System
Analysis &
Capability
Define
• Identify
Product/
Process
Performance
& Reliability
CTQ’s
• Set Quality
Goals
• QFD
Product / Process DFSS -- 14 Steps
Analyze
• Develop
Conceptual
Designs
• Statistical
Reliability
Analysis
• Build
Scorecards
• Risk
Assessment
Type I
Error
a
Type II
Error
b
Correct
Decision
(1-a)
Correct
Decision
(1-b)
Verify
• Statistically
Confirm that
Product /
Process
Matches
Predictions
• Develop
Manufacturing
& Supplier
Control Plans
• Document &
Transition
1 2
3
4
5
6
7
8
9
10
11
12
13
14
Design
• Build System
& Sub-
System
Models
• Generate
Transfer
Functions
• Statistical
Analysis of
Variance
Drivers
• Process
Capability
Flow-up for
All
Subsystems
Optimize
• Optimize
Design
• Robust
Design
• Error Proofing
• Generate
Purchasing &
Manufacturin
g Specs
Measure
• CTQ
Flowdown to
Subsystems
&
Components
• Measurement
System
Analysis &
Capability
Define
• Identify
Product/
Process
Performance
& Reliability
CTQ’s
• Set Quality
Goals
• QFD
Product / Process DFSS -- 14 Steps
Analyze
• Develop
Conceptual
Designs
• Statistical
Reliability
Analysis
• Build
Scorecards
• Risk
Assessment
Type I
Error
a
Type II
Error
b
Correct
Decision
(1-a)
Correct
Decision
(1-b)
Type I
Error
a
Type II
Error
b
Correct
Decision
(1-a)
Correct
Decision
(1-b)
Verify
• Statistically
Confirm that
Product /
Process
Matches
Predictions
• Develop
Manufacturing
& Supplier
Control Plans
• Document &
Transition
1 2
3
4
5
6
7
8
9
10
11
12
13
14
Steps involved in DFSS

7. WHAT TO DO ?

8. 1. DEFINE
The best way and the first thing to do is Identifying the CTQ’S
Why VOC?
“customer perceived quality is a leading device of business success”
 What is CTQ?
Ask customer a feedback about his expectation and experience
of product and service. (VOC)
VOC
What are the needs and
wants
What kind of service or
products are required

9. S NO BUSINESS CASE DATA
1. Business case
-Explanation of why to do this project
2. Problem and goal statement
–Description of the problem/opportunity or
objective in clear, concise, measurable terms
3. Project scope
–Process dimensions, available resources
4. Milestone
-Key step and dates to achieve goal
5. Roles
-people ,expectations and responsibilities.
FIVE MAJOR ELEMENTS
Go to Design sheet

10. 2. MEASURE
 Perform CTQ’S flow down to identify technical requirements - Go to design sheet
 Establish Data Collection Plan Validate Measurement System & Collect Data
Optimize the measurement system with minimizing bias and variable
The over all efficiency will increases if we reduces these variables.
BIAS
VARIABLE
One side
lacking a
neutral point.
Common
cause
Special
cause
Which are natural
that you can not
eliminate
Which are directly
caused by
something special.

11.  So with the six sigma measurement we spend a particular time on understanding these
(common,special) causes.
 We can identify which type is causing the variation and how it is effecting.
 How to determine:
Calibration study Gauge R&R
( Repeatability & Reproducibility)
The average observed variance differs
from actual process average then BIAS is
present.
The shift of the centering of the data is
related to gage accuracy and this is
adjusted by calibration.
If the observed variance is larger than the
actual variance then the difference is due
to the measurement error.
Bias error can be minimized only by
calibrating known samples.
We do this to detect or correlate any
variation this way an adjustment can be
made to eliminate measurement error.

12. 3. ANALYZE
Here we analyze which problems are causing the failure. So we use the different tools for finding the failure.
 Primary concepts - CTQ’S
 Benchmarking - It is a conceptual analysis to establish a base line and best in class goal
For your product process and methodology.
 Brainstorming - Generate new ideas and build on individual thoughts.
 Establishing primary concepts - Start thinking about a brand new solution.
 Working on specification conflicts - Technical contradiction
physical contradiction.
Go to Design sheet

13.  FMEA -Failure Mode Effective Analysis
process Severity
1-10
Occurre
nce
1-10
Detecti
on
1-10
RPN
S.O.D
CAP 3 2 1 6
FELT TIP 5 7 6 210
BODY 2 3 2 12
ASSEMBL
Y
3 6 2 36
Actions for reducing risk:
 Design changes
 Engineering safety features
 Safety devices
 Warning devices
RPN=Risk priority Number

14.  PUGH MATRIX
 Which item or potential solution are more important or better than other It is employed after
capturing voice of customers.
 It is a scoring matrix used for concept selection in which options are assigned scores relative
to criteria.
 The selection is made based on consolidated score , before starting the design there are many
options – this tool helps in selecting the best option

15.  RISK ASSESMENT
 Go to design sheet 7
WATER FALL CHART
DATE – X axis
RISK – Y axis

16. 4. DESIGN
DESIGN OF EXPERIMANT

17.  REGRESSION ANALYSIS
 We find the errors by using Regression analysis.
 It is a simple empirical mathematical model which correlates system variable and response
Y^=bº+b1X
X- Independent variable
Y- Dependent variable
b1- slope of line
Downwards (-)
upwards (+)
b◦ - point on y
y
X
Independent variable
D
e
p
e
n
d
e
n
t

18. Regression line graph:
X- Independent variable
Y-Dependent variable
b1- slope of line
Downwards (-)
upwards (+)
b◦ - point on y

19.  CTQ FLOW DOWN
 By doing this process it is easy to design the product or process.
 By breaking down the product into process key functions which we can begins to conceive the
solution.
 Find the requirements of each functions and how to satisfy that level.
 Why it is important:
 It provides the foundation for looking the different concepts.
 And linking this concepts to CTQ and ensure that you are designing the correct set of
requirements.
 Why Tree diagram:
 By dividing it makes you to scope more manageable.
 Allows the team members to check all high level problems and solutions.
 It allows team to check all levels from a visual perspective.
“ It expands the concept in greater details”

20. 5.OPTIMIZE
Here we use Robust design and the Tolerance road map process for optimizing the design
process.
THE goal is to identify the near optimal design point.
Why robust design?

22.  Fishbone Diagram
It helps you to identify many potential causes for a specific problem or effect.
Tolerance road map- Go to design sheet
Material
EnvironmentMan
Maintenance
Hard
suspension
Improper Servicing
Wrong Hydraulic Fluid
Faulty Parts
Amateur Rider Sex
Fatigue Strength
Spring Material
Weather
Road Condition
Physical condition
Proper Spring
Wet surrounding
Yield Strength

23. 6.VERIFY
Statistically Confirm that Product / Process Matches Predictions
1. Transfer function validation Correct the relationship between the y’s and x’s
2. Part process validation/ first
piece analysis
Check the individual pieces to ensure part meets
requirements set on the diagram.
3. Performance verification Verify the performance under the controlled
condition
4. Finding and fixing failure
mode
Does this design meet our reliability target?
By doing this we can find our failures so we can
optimize them again for giving better output.

24. 7.VALIDATION
 Develop manufacturing and supplier control plan
 Documents and transition.
 What is control plan?
It is the strategy for maintaining the design performance over time.
 Why?
 It ensures the consistency of design performance on the CTQ s
 It provides a detail information transition to operation and allowing operation to reach
optimal performance quickly and without mistake.

27. PROJECT CLOSE
 Capture lessons learned
 Document projects best practice
 Identify opportunities for improvement
 Evaluate efficiency of all development processes used
 Validate project(Actual vs estimated )
 Communicate the ending
 Celebrate the success.

28. Share knowledge to gain more knowledge

29. Chaitanya chenna