Post on 23-Dec-2015
Phong Q. Vo
Dec 2, 2011
Design For Six Sigma &Design For Six Sigma &Structured InnovationStructured 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
0.4
3
1.1
7
1.9
2.6
4
3.3
7
4.1
1
4.8
4
5.5
8
6.3
1
7.0
4
7.7
8
8.5
1
9.2
5
9.9
8
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 spec
Out spec left
Out spec right
LSL
USL
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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Sdfsdfsd
Sdffsdf
Czxczxc
Czxczxc
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