Design for Six Sigma (DFSS)
- Examine what Design for Six Sigma is and its importance
- Understand why DFSS is important to Six Sigma implementation.
- Understand robust design and functional requirements.
- Develop a robust design using noise strategies. Understand the concepts of tolerance design and statistical tolerancing.
- Calculate tolerances using process capability data.
A. Common DFSS methodologies
Identify and describe these methodologies. (Understand)
1. DMADV (define, measure, analyze, design and validate)
2. DMADOV (define, measure, analyze, design, optimize and validate)
Describe design constraints, including design for cost, design for manufacturability and producibility, design for test, design for maintainability, etc. (Understand)
C. Robust design and process
Describe the elements of robust product design, tolerance design and statistical tolerancing. (Apply)
D. Special design tools
Describe how Porter’s five forces analysis, portfolio architecting and other tools can be used in strategic design and planning. (Understand)
- Business outcome is showing ‘stair shaped graphs.’
- New products / services / processes
- Exponential change
- Introduction of new technology
Why Use DFSS?
Business studies by Hockman (2001), Suh (1990), and Paul (1996) found that 70-80% of quality problems are design related.
DMADV stands for Define, Measure, Analyze, Design, and Verify. It requires a large scope and budget and requires exponential amounts of change. This kind of an event could be triggered by new research or technology breakthroughs, a mandate to leap frog the competition, radical new customer requirements, new regulations or legislation.
Resources are typically allocated earlier in the cycle than regular design.
Success depends on the involvement of senior management, the team retaining a customer-centric focus, fostering creative design, and executing sound project management.
- Design Phase
DMADV vs DMAIC
- Use when designing a new process, product or service.
- Creating exponential change for your business.
- Introduction of new technology.
- Uses SIPOC
- Use to improve an existing process
- Just focus on customer
- Customer’s needs & requirements
- Develop / Design Phase
- Parameter design
- Tolerance Design
- Verify and Validate
DMADOV is an acronym that stands for:
- The goals
- customer requirements
- Measure the opportunity
- Determine needs and specifications
- benchmark opportunities
- Examine options
- Determine creative solutions
- Design Phase
- Develop a product and process
- Design experiments to verify design meets customer needs.
- Evaluate performance levels and impacts
- Redesign as necessary
- Process abilty to meet customer needs
- deploy the new process.
Additional Tools / Notes
Set based design
design methodology that incorporates concurrent engineering, taguchi robustness concepts, and convergence techniques
design solution using a broad set of possible solutions, converging to a narrow set of alternatives, and then to a final solution
means minimize noise or make output insensitive to noise; experimentation and testing
Noise factors are not controllable by the designer, for example: Weather
Order is System (Concept) design, Parameter Design and Tolerance Design
Enhance technical processes to prevent design issues; uses IDEA process
links design processes to technical process and then to marketing and service support functions
Enhancing technical processes to prevent design issues
Links product performance to system parameters and then to product developmental activities
Defined downward flow of requirements that are directly linked to necessary engineering functions to fulfill the requirements
Systematic Design – German methodology that uses 4 steps (Clarify the task, Develop a conceptual design, Refine the design, Generate the final detail design)
New product characteristic with lowest importance – is being first to the market
13 New product characteristics include A unique superior product, A strong Market Orientation, Pre-development work, Good Product Definition, Quality of Execution, Team effort, Proper Project Selection, Prepare for Launch, Top Management Leadership, Speed to Market, A new product process, An attractive market, strength of company abilities