Phong Q. Vo

Nov 30, 2012

Design For Six Sigma &Structured Innovation

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Credentials B.A.Sci. in Mechanical Engineering, UW, 1989 M. Eng.in Mechanical Engineering, UWO, 2003 M.B.A., WLU, 2006 Certified DFSS BB since 2007 A member of PEO since 1993 GM/GDLS employee since 1990, held various

positions in engineering department (Design, Computer Modeling & Simulation, Engineering Quality, Systems Engineering)

A good friend of Dr. P. Kurowski

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Topics of Discussion Definition of Quality What is 6 sigma? 6 sigma benchmark Lean six sigma (LSS), Design For Six Sigma

(DFSS), Differences Phases in a DFSS project Structured Innovation & TRIZ Questions

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Definition of Quality “A characteristic or attribute of something;

property; a feature” – The Houghton Mifflin Canadian Dictionary

“Characteristic of a product or service that satisfies the customer's wants and needs in exchange for monetary considerations” - Web definition

“High quality product or service can only be achieved by well/systematically designed process, disciplined execution, and the right attitude of the people involved” – P.Q.V.

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What is Six Sigma ? A disciplined, statistically driven methodology for

eliminating or reducing defects (or waste) in any process.

Originally developed by engineers at Motorola in the 1980’s to improve the company’s quality monitoring process.

To day, the six sigma principles are used worldwide as a management tool to improve business outcomes.

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An illustration

Cpk Analysis

-9.1

-8.4

-7.6

-6.9

-6.2

-5.4

-4.7 -4

-3.2

-2.5

-1.8 -1

-0.3

0.43

1.17 1.9

2.64

3.37

4.11

4.84

5.58

6.31

7.04

7.78

8.51

9.25

9.98

10.7

11.5

12.2

12.9

13.7

14.4

15.1

15.9

16.6

17.3

18.1

18.8

19.5

In specOut spec leftOut spec rightLSLUSL

Mean = 5.5512StdDev = 3.2593USL = 15LSL = -4Sigma Level = 2.8991Sigma Capability = 4.1909Cpk = .9664Cp = .9716DPM = 3,564N = 5

Process to meet control limits

Control Limits established to meet customer expectations

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SdfsdfsdSdffsdfCzxczxcCzxczxc

czx

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6 Sigma Process Benchmark

Sigma Level DPM Assessment

1 sigma 697,672 Non-competitive

2 sigma 308,770 Non-competitive

3 sigma 66,811 Non-competitive

4 sigma 6,210 Industry Average

5 sigma 233 Industry Average

6 sigma 3.4 World Class

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What is Lean Six Sigma (LSS)?

The application of lean six sigma philosophy to produce better products, at faster rates, and at lower costs. Lean means eliminating non-value added steps in a

process. Six Sigma means reducing variation of a lean process.

In other words, the process produces no more than 3.4 defects per million.

Synonymous with DMAIC (Define, Measure, Analyze, Improve, Control)

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What is Design For Six Sigma (DFFS)? A proactive, predictive, and systematic design

approach to develop six sigma quality level products or services.

Synonymous with DCOV (Define, Characterize, Optimize, Validate)

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Main Differences between DFSS and LSS ?

LSS DFSSReactive Proactive

identifies problems and modifies existing processes

concentrates on up-front designs and processes

Benefits are easy to quantify

Benefits are long-term.

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Phases in a DFSS project

Define

Characterize

Optimize

Validate

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Define Phase

Voice of Customers (VOC) House of Quality #1 CTC (Critical to Customers) Balance Scorecard (Parts, Process, Performance,

Software)

Define

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Characterize Phase

Systems Engineering & Requirements Flow-down House of Quality #2 Creation of Transfer Function (DOE, EVA) Design Concept Development Design Risk Assessment Design Concept Selection

Characterize

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Optimize

Design for Robust Performance Tolerance Allocation Design for X (Manufacturability, Reliability,

Maintainability, Assembly, etc.) Product Capability Prediction

Optimize

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Validate

Prototype construction Predicted vs. Actual comparison Sensitivity Analysis

Validate

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Structured Innovation - TRIZ

TRIZ stands for “Teoriya Resheniya Izobreatatelskikh Zadatch” (A Russion acronym). It means “Theory of Inventive Problem Solving”

Genrich Altshuller, the father of TRIZ Born in Oct. 1926, in Tashkent, USSR Died on Sept. 24th, 1998 in Petrozavodsk, Russia. An engineer, inventor, scientist, journalist, and

writer. The story of G. Altshuller at Gulag concentration camp

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More on Altshuller & TRIZ

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More on Altshuller & TRIZ Altshuller screened over 200,000 patents and

looked for patterns in problem solving techniques

Altshuller concluded that There are a finite number of potential problems

and solutions in the universe Innovation is a solution resolving major design

conflicts (physical & technical contradictions)All problems can be framed within 39

parametersThey can be solved using 40 principles

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Traditional Problem Solving Process

Problem A Ideal Solution

Traditional Problem Solving Process

The Wall

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TRIZ Process

Problem A Ideal Solution

TRIZ Process starts here

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TRIZ Process

Specific Problem

Generic Problem

Generic Solution

Specific Solutions

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Questions