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Developing DFSS Capabilities Through Simulation

WCBF Design for Six Sigma Conference

June 9, 2005 – Las Vegas, Nevada

Maurice Klaus

Peg Pennington

The Case for Simulation in DFSS Training

Learning Objectives – Three Questions:

• What is the current DFSS landscape?

• What are the limitations of DFSS instruction?

• How could it be better?

• Introductions

• DFSS Definitions

• DFSS Training Today

• e-Learning Survey

• Simulation Based DFSS Training

Outline

Competing Definitions

DCDOV CDOV DMADV DMADOV IDOV IDDOV DCCDI DMEDI

Define

Concept

Define Define

Identify

Identify Define Define

Measure Measure

Define

Customer Measure

Concept Analyze Analyze Concept Explore

Design Design Design Design Design Design Design Design

Optimize Optimize

Verify

Optimize Optimize Optimize

Implement Implement

Verify Verify Verify Validate Verify

Design Design Design Design Design Design Design Design

Why DCDOV?

Define Measure Analyze

Improve Control

Design Verify

DMAICImprovement

DMADVRedesign

Existing Processes ?

Define Concept Design Optimize VerifyDCDOV - DFSS

Design / Redesign

Discussion

• What is your experience with DFSS training?

Tool / M

ethod

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DFSS Training Today

Wide and ShallowNarrow and DeepBalanced is Needed

Training Delivery Methods Report Card

Critical To Quality Characteristics Classroom Online BlendedAdministrative Burden C A B Consistent Quality C A ACustomization - Local Content A C BCost - Instruction, Travel, Facilities, Binders F A BConfigurable C A BEffective Skill Building - Project Application B B AEfficiency - Time Spent Where Needed D A BFacilitates Teamwork A D BFlexibility - Geography D A BFlexibility - Scale D A BFlexibility - Time F A BHands On Practice A F BInteractive Practice B A AManageable Bites F A AMatch Learning with Doing D B BProject-specific Coaching A D BReal Time Support A D AReference - On Demand D A A

What Do Students Value?

Desired Features

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5%

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Simulations Practice Articles Examples Case studies Audio

Feature

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...and focused

• Balance... – Between Wide & Shallow and Narrow & Deep

What is Needed?

Tool / M

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What is Needed?

• Modularity... – Can be arranged to meet specific needs

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What is Needed?

• ...With The Features Students Want– Simulations– Practice– Articles– Examples– Case Studies– Audio

DFSS at MoreSteam.com

• Content

DFSS at MoreSteam.com

• DeliverablesPHASE DELIVERABLE

Define

Project Charter

Project Plan

Target Markets / Segments

Customer Wants and Needs

Critical to Quality Characteristics

Technical Features and Component Specifications

ConceptCTQC Measures

Optimal Design Concept

Design

Process Parameters

Design Model

Developed Design

Design Scorecard

Optimize Optimized Design

Verify

Control Plan

Test Plan and Report

Pilot Plan and Report

Project Close-Out

Verified Design

• Features– Simulations– Practice– Articles– Examples– Case Studies– Audio

DFSS at MoreSteam.com

Simulation in DFSS Training

• Roller Coaster Tycoon®

– Non-traditional approach (patent pending)– Gaming to teach DFSS techniques– Supplement to each course session– Design and implement improvements to

underperforming amusement park– Immediate application of techniques learned– Transactional process

Simulation in DFSS Training

• Project Charter– Mission & Scope

Simulation in DFSS Training

• Voice of The Customer

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Affinity Diagram

CTQC Tree

Simulation in DFSS Training

• Concept Selection

Simulation in DFSS Training

• Metrics

Design Scorecard

Simulation in DFSS Training

• Transfer Function– Multiple regression

Simulation in DFSS Training

• Testing

Simulation in DFSS Training

• Launch

Six Flags Texas Giant

Conclusion

• Questions?