17 OneWkWrapUp Final

8/22/2019 17 OneWkWrapUp Final

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© 2001 Six Sigma Academy

Course Wrap-Up

DFSS One Week Course




Module Objectives

• By end of module, participant will be able to:

• Articulate major DFSS phases and steps

• Recall tools used in DFSS for business process




What is Design for Six Sigma?

Designing products, services, and processes that satisfyboth client and business needs at six sigma quality.

“Design with the Power of Six Sigma”




DFSS Phases and Activites

Identify ValidateDesign Optimize

• Secure leadershipcommitment

• Scope project,align resources

• Establish systemof projectmanagement

• Gather the client

requirements(CTS)

• Assess thecompetition

• Establish thefunctionalrequirements

• Generate the designrequirements

• Develop conceptualdesigns

• Develop preliminary

designs• Evaluate alternatives

• Develop detaileddesign

• Establish transfer functions

• Predict designperformance

• Simulate design• Prepare control plan

• Pilot new design• Confirm client

requirements aremet

• Implement newdesign




DFSS Steps & Tollgates

• Tollgates are formal reviews of a DFSS project at conclusion of each DFSS

step

• Cross functional meetings of project decision makers

• Decision point for project continuation

Client

Needs

T ol l g a t e 1

T ol l g a t e 2

T ol l g a t e 3

T ol l g a t e 4

T ol l g a t e 5

• Gather needs

• Translate needs toCTS’s

• Translate CTS’s to

functionalrequirements

•Assess technology

• Develop plan

• Assess risk

• Translate functionalrequirements todesign parameters

• Develop/evaluatedesign alternatives

• Resolve designconflicts

• Assess risk

• Flow down systemdesign to subsystems

• Design for assembly,reliability,maintainability

• Mistake proof design

•Assess risk

• Develop transfer functions

• Develop systemcapability

• Assess design gaps

• Optimize design

• Assess risk

• Run pilot/build prototype

• Validate design

• Verify systemcapability

• Assess risk

T ol l g a t e 6

6 Sigma

Processes

Conceptual

Design

Preliminary

Design

Detail

Design

Pilot/

PrototypePre-Launch Launch

T ol l g a t e 7

Identify ValidateDesign Optimize

• Demonstrate process/ product capability

• Mistake proof process

• Assess risk

• Monitor systemcapability

• Implement design and process control plans

• Develop transition plan




Tollgate #1

Deliverables Tools

• Project Charter • Project Plan

• Change Plot

• Gather Client Needs Surveys, Interviews

• Translate Needs to CTS’s QFD (House #1)

• Translate CTS’s to Functional QFD (House #2)

Requirements• Assess Technology Technology Roadmap

• Technology Benchmark Technology Roadmap

• Competitive Benchmark

• Financial Analysis ROI, DCRR

• Project Risk Assessment


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Tollgate #2

Deliverables Tools

• Concurrent Development Plan Process Checklist• Potential Solutions Identified TRIZ

• Solutions Evaluation Pugh Matrix

• Design FMEA

• Design Scorecard

• Updated Change Plot




Tollgate #3

Deliverables Tools

• Systems to Sub-system FlowDown

• Translate Functional Require- QFD (House #3)ments into Design Requirements

• Additive Design

• Reliable Design

• Mistake Proof Design Poka-Yoke• Procurement Strategies Concurrent Checklist

• Updated Design Scorecard





Tollgate #4

Deliverables Tools

• Experimentation DOE• Parameter Design

• Transfer Functions Established

• Requirements Flow Down

• Design Conflicts Resolved

• Capability Flow Up

• Optimized Design

• Statistical Tolerances Established




Design/Optimize



Tollgate #5

Deliverables Tools

• Create Test Environment• Run Pilot/Build Prototype

• Validate Design







Tollgate #6

Deliverables Tools

• Tolerance Design• Mistake Proof Manufacturing Poka Yoke





Optimize/Validate



Tollgate #7

Deliverables Tools

• Implement Design Plans• Implement Control Plans

• Transition Plans




• Final Project Documentation

• Lessons Learned

Validate



DFSS Tips

• Complete project charter early• Leadership and cross functional participation in tollgate reviews

crucial

• Update “living” documents throughout process

• Design scorecard

• Change plot

• Project risk assessment

• Adhere to DFSS process




Key Learning Points

• •

•

•




Module Review

• Participant should now be able to:

• Articulate major DFSS phases and steps

• Recall tools used in DFSS for business process



Trademarks and Service Marks

Six Sigma is a federally registered trademark of Motorola, Inc.

Breakthrough Strategy is a federally registered trademark of Six Sigma Academy.

VISION. FOR A MORE PERFECT WORLD is a federally registered trademark of Six Sigma Academy.

ESSENTEQ is a trademark of Six Sigma Academy.

FASTART is a trademark of Six Sigma Academy.

Breakthrough Design is a trademark of Six Sigma Academy.

Breakthrough Lean is a trademark of Six Sigma Academy.

Design with the Power of Six Sigma is a trademark of Six Sigma Academy.

Legal Lean is a trademark of Six Sigma Academy.

SSA Navigator is a trademark of Six Sigma Academy.

SigmaCALC is a trademark of ix Sigma Academy.

SigmaFlow is a trademark of Compass Partners, Inc.

SigmaTRAC is a trademark of DuPont.

MINITAB is a trademark of Minitab, Inc.

Documents

17 OneWkWrapUp Final