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Example of DFSS Project
The document details the application of Design for Six Sigma (DFSS) in the SecureKey project at Ingersoll Rand, highlighting the method's focus on customer needs and quality management through tools like Quality Function Deployment (QFD) and Design of Experiments (DOE). It emphasizes the importance of critical to quality (CTQ) metrics in product design and the successful outcomes of the team, including significant financial benefits from the SecureKey product. The document also acknowledges team members and their contributions to achieving DFSS Greenbelt certification.
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Example of DFSS Project
- 1. DFSS in NewProduct DevelopmentCase Study of the Securekey Projectby Ray BalisnomoApril 21, 2010: Version 6
- 2. This DFSS Approachis NOT PracticalProject goals
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- 4. Create teamDefineCapture voiceof the customer
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- 8. Review riskassessmentAnalyzeDevelop models
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- 11. Optimize designOptimizeCompare productto initial specs
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- 13. DFSS in Practiceat Ingersoll RandDFSS Design ScorecardQuality Function Deployment (QFD)PredictWe use the other DFSS Tools (e.g., DOE, Regression, Pugh matrix, ANOVA, etc.) to close the gap between what the customer desires & how the actual product performs..ValidateCustomer NeedsCustomer SatisfactionSystem DesignSystem CapabilitySubsystem DesignSubsystem CapabilityComponent DesignComponent CapabilityProcess DesignProcess CapabilityCritical to Quality (CTQ) Management
- 14. Kano AnalysisBasic Needs(e.g., Test Requirements)Customer surveys or interviews (Focus Groups)MarketingRequirements DocumentPerformance needsExcitement needs or DelightersProduct SpecificationsAHP Pair-wise ComparisonPrioritized or WeightedCustomer Needs (WHAT’s) Quality Function Deployment (HOQ-1)System-level CTQ’s.HOW do we measure success?
- 15. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsSystem DesignCritical to Quality (CTQ) Management
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- 17. Pugh Matrix forConcept Selection
- 18. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsSystem DesignSubsystem DesignCritical to Quality (CTQ) Management
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- 20. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsSystem DesignSubsystem DesignComponent DesignCritical to Quality (CTQ) Management
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- 22. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsDesign of ExperimentsSystem DesignSubsystem DesignComponent DesignCritical to Quality (CTQ) Management
- 23. Design of Experiments:Recombinating Sidebar Spring Retention
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- 25. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsDesign of Experiments
- 26. Gauge R& RSystemDesignSubsystem DesignComponent DesignCritical to Quality (CTQ) Management
- 27. Measurement System Analysis:Surface Roughness(Ra) Lck.Sidebar
- 28. DFSS in Practiceat Ingersoll RandQuality Function Deployment (QFD)PredictCustomer NeedsDesign of Experiments
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- 30. Regression AnalysisSystem DesignSubsystemDesignComponent DesignCritical to Quality (CTQ) Management
- 31. Binary Logistic Regressionto Determine Upper Spec. Limit for Surface Roughness for Locking Sidebar
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- 33. DFSS in Practiceat Ingersoll RandDFSS Design ScorecardQuality Function Deployment (QFD)Design of Experiments
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- 35. Regression AnalysisPredictValidateCustomer NeedsSystemDesignSubsystem DesignComponent DesignComponent CapabilityCritical to Quality (CTQ) Management
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- 37. Tolerance Stack-ups usingMonte Carlo Simulation
- 38. DFSS in Practiceat Ingersoll RandDFSS Design ScorecardQuality Function Deployment (QFD)Design of Experiments
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- 40. Regression AnalysisPredictValidateCustomer NeedsSystemDesignSubsystem DesignSubsystem CapabilityComponent DesignComponent CapabilityCritical to Quality (CTQ) Management
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- 42. Capability Studies: PlugPull Strength
- 43. DFSS in Practiceat Ingersoll RandDFSS Design ScorecardQuality Function Deployment (QFD)Design of Experiments
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- 45. Regression AnalysisPredictValidateCustomer NeedsSystemDesignSystem CapabilitySubsystem DesignSubsystem CapabilityComponent DesignComponent CapabilityCritical to Quality (CTQ) Management
- 47. DFSS in Practiceat Ingersoll RandDFSS Design ScorecardQuality Function Deployment (QFD)Design of Experiments
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- 49. Regression AnalysisPredictValidateCustomer NeedsCustomerSatisfactionSystem DesignSystem CapabilitySubsystem DesignSubsystem CapabilityComponent DesignComponent CapabilityCritical to Quality (CTQ) Management
- 50. Financial BenefitSecurekey becauseit’s sold as part of a complete lock generates $250Million per month, or $8.33 Million per day.As a stand-alone product, the key & cylinder generates at least $70,000 a day in operating income or profit
- 51. Security, ColoradoSajil MathachanKentBarkerScott WelsbyJason CliffordBrian WallsVAVE EngineerLeader of Design TeamDesign EngineerDesign EngineerDesign Engineer & InventorCongratulations Secure Key Teamon achieving DFSS Greenbelt CertificationTeam Members in Bangalore India (not pictured) : Ajeya Rao, Subashchandra Rai, and Jonah Pattar
Editor's Notes
- #3 If you’ve been taught DFSS but have never practiced it, chances are this is what you think the methodology looks like. But if you actually put it into practice, you will find this model to be use-less. It’s only “Good” in theory. In the real world, no one applies DFSS using the DMADV phase gate process. Unlike DMAIC, DFSS is not a linear process. There’s a creative element that forces you to drill down into the details. The following presentation is about how DFSS is used in the real world.