The key customer requirements for the Max Gravity Breaker device are to separate asphalt mix within specific size and time constraints. The requirements include: - Separating 1500g of mix within one hour or 15 minutes - Accepting mixes with aggregate sizes between 4.75mm and 1.5 inches - Producing separated particles smaller than the largest aggregate pieces - Operating automatically and completing separation for under $5000

1. Design for Six Sigma Department of Mechanical Engineering

2. DFSS: A systematic methodology of integrating statistical tools into product and process development to achieve predictive design quality and meet VOC requirements.

4. DMAIC or DFSS Project? O ptimize Define Measure Analyze Improve Control Does a Process Exist? Is Incremental Improvement Enough? Is the Improvement a New or Redesigned Product or Process? D esign C oncept No No Yes Yes No Yes DMAIC Process DFSS Process C apability

5. Problem Definition Conceptual Design Embodiment Design Detail Design Communication of the Design

7. Critical Parameter Management Houses of Quality Usage Voice of the Customer Needs Mfg. Process CTF Specs Cp System Level Requirements Subsystem Level Requirements Subassembly Level Requirements Component ‘ Critical to Function’ (CTF) Req’ts. Mfg. Process Requirements Component CTF Specs…. Cp Subassembly Critical Function Response (CFR) Cp Subsystem Level CFRs….. Cp System Level CFR’s Cp

9. Roadmap: Where are we going? Voice of the Customer Needs Benchmarking House of Quality System Level Product Design Specification Functional Analysis Systems Engineering Interviewing the Customer

14. Stage 1: Experience their world Problem Definition Determine Which Customers to Visit Develop Discussion Guide Visit Customers Develop Image of Customer’s Environment and Needs

17. Case Study: You work for a company that manufactures and sells flashlights. Sales are dropping. Your goal is to increase both sales and profits.

18. What would you want in a new flashlight? What bugs you about current flashlights?

28. Stage 2: Transform our Understanding into Customer Requirements Collect Voices from Interviews Identify Key Voices Link Voice with Image to Give Context Develop Image of Customer’s Environment and Needs Collect Potent Images of Product Use Extract Key Ideas or Essences Translate Requirements to Our Language

29. Interview Transcription You will get two kinds of information. Images Voiced Requirements or Needs Of the context/ environment of use Needs Ideas Complaints Questions Suggestions Solutions Easy to spot!

31. WHAT SCENES AND IMAGES DESCRIBE KOCH’S PROCESS FOR BREAKING UP MIX? RUBBING BETWEEN TOWELS DOESN’T SEPARATE MIX LEAF BLOWERS DON’T SEPARATE MIX THERE ARE PROCESSES THAT ARE NOT SUCCESSFUL FOR SEPARATING THE MIX . THEY RUB THEIR HANDS BACK AND FORTH WITH MIX BETWEEN THEIR HANDS TO MAKE IT COME APART. THEY USE A SPATULA TO SPREAD THE MIX OUT ON A TABLE WHEN IT IS TOO HOT TO HANDLE THERE ARE CURRENT PROCESSES THAT THEY USE TO SEPARATE THE MIX. MANY PROCESSES HAVE BEEN TRIED TO SEPARATE THE AGGREGATE THE EMPLOYEES ARE EXCITED ABOUT WORK THE COMPANY IS INNOVATIVE EMPLOYEES ARE WILLING AND EXCITED TO EXPERIMENT THE CUSTOMER HAS A CAN DO ATTITUDE THERE IS AN ASSEMBLY LINE OF MIX WAITING TO BE BROKEN APART BREAKING APART THE MIX IS TIME CONSUMING THEY USE A LOT OF TABLE ROOM TO SPREAD OUT THE HOT MIX TO KEEP IT FROM STICKING THEY PUT TAPE ON THEIR FINGERS BECAUSE THE MIX IS SO ROUGH IT IS HARD TO BREAK APART THE MIX AND IT HURTS YOUR HANDS PROCESS IS SPACE AND LABOR INTENSIVE WITH HIGH VOLUME THE PROCESS IS PAINFUL PROCESS HAS CHALLENGES THAT NEED TO BE OVERCOME MIX IS LIKE A FLUID WHEN HOT THE MIX STARTS OUT HOT BUT COOLS QUICKLY PROCESS INVOLVES RAPID HEAT TRANSFER THAT CAUSES MATERIAL PROPERTIES TO CHANGE THE COOLED AGGREGATE IS ALL STUCK TOGETHER THE CONSISTENCY IS LIKE RICE KRISPIE TREATS WHEN YOU POUR IT OUT MIX IS STICKY SOME COOLED MIXES ARE BONDED TOGETHER THE SMALLEST OPENING IS ABOUT 4.75 MM ON A SIDE THE SEPARATED MIX MUST BE SMALLER THAN THE LARGEST ROCK IN THE MIX PROCESS HAS SIZE CONSTRAINTS THE CURRENT PROCESS HAS CERTAIN PROPERTIES   

34. 1. “Give me one whole thought from your interview…” 2. “Now pick out any image from your visit that relates to that voice..” 5. “Does that voice connect differently with another image?” etc. 3. “What thoughts come to mind when you link those two? Any others?—Note all of them.” 4. “Take a stab at figuring out what their requirement is. Does your first line sound like a solution, if so what are you solving? Is the statement as concrete as you can make it?” Several iterations are normal and desirable!! Translation Worksheet Number Name Any Images: Key Items: Customer Requirement(s)/Needs(s): Customer Voice:

35. Every time my wife and I talk about home theater systems, she complains that we have a beautiful decorated house that wasn’t designed to include a home theater system. The bulky mass module – I didn’t want to see it first thing when we walked into the room – so we moved it to the other side. Disappointed with the way it looks after installation. 1 st try: Homeowner has to do minimal alterations in the room to accommodate systems in desired locations. 2 nd try: Homeowner has minimal awareness of the system. 3 rd try: System components are well matched and unobtrusive. Home Entertainment System Translation Worksheet Number Name Any Images: Key Items: Customer Requirement(s)/Needs(s): Customer Voice:

36. Cars can’t go to court… so we use photos to show if the vehicles hit each other or not… the photo has to have clear detail to show paint transfer from one car to another after collision. If there was no collision, then no accident. Detailed picture proved that cars didn’t hit each other. Need detail in photos, details used as evidence, need to see paint transfer. 1 st try: Photo shows details of car collision. 2 nd try: Details in photo evidence transfer of paint from one car to another after collision. 3 rd try: Photos show to the naked eye paint transfer between cars. Translation Worksheet Number Name Any Images: Key Items: Customer Requirement(s)/Needs(s): Customer Voice:

37. It should be able to handle different sizes. 1 st try: Device should accept mixes with different size of aggregate. 2 nd try: Device should accept mixes that contain aggregate from 4.75 mm to 1.5”. Size varies They use both English and metric units. Translation Worksheet Number Name Any Images: Key Items: Customer Requirement(s)/Needs(s): Customer Voice:

40. 3. “What thoughts come to mind when you link those two? Any others?—Note all of them.” “ When I’m standing in line at the cashier trying to find my checkbook while balancing my bag on my knee, I feel like a stork.” Translation Worksheet Quiz#3 CM Name Any Images: Key Items: Customer Requirement(s)/Needs(s): Customer Voice:

42. WHAT ARE THE KEY CUSTOMER REQUIREMENTS FOR THE MAX GRAVITY BREAKER? DEVICE SHOULD BE OPTIMIZED FOR 1500 GRAMS. DEVICE SHOULD HANDLE 500 – 600 GRAMS DEVICE HAS VOLUME REQUIREMENTS THE SMALLEST AGGREGATE SIZE IS A 4.75 MM SIEVE. THE LARGEST SIZE IS 1.5” SEPARATED PARTICLES MUST BE SMALLER THAN THE LARGEST PIECE OF AGGREGATE THERE ARE SIZE REQUIREMENTS FOR THE MIX THE DEVICE HAS PHYSICAL CONSTRAINTS DEVICE IS COMPLETELY AUTOMATED DEVICE MUST SEPARATE MIX IN ONE HOUR DEVICE SHOULD SEPARATE MIX IN 15 MINUTES THERE ARE TIME REQUIRE-MENTS FOR THE PROCESS MINIMIZE COST KEEP COST UNDER $5000 THERE ARE COST LIMITS THE DEVICE HAS ECONOMIC CONSTRAINTS DEVICE SHOULD OUTPUT COOL, SEPARATED MIX AFTER EXITING THE DEVICE, ASPHALT MUST ADHERE TO AGGREGATE AGGREGATE IS INTACT AFTER PROCESSING THERE ARE REQUIREMENTS FOR THE OUTPUTS FROM THE DEVICE THE DEVICE HAS SPECIFIC INPUT/OUTPUT REQUIREMENTS DEVICE HAS REQUIREMENTS FOR ACCEPTING THE MIX ALL MIX MUST ENTER THE DEVICE DEVICE SHOULD ACCEPT MIXES WITH DIFFERENT SIZES OF AGGREGATE DEVICE SHOULD ACCEPT MIX AT 170 C  