Introduction to Design for Sigma Developed By Toolkits/The DFSS... · OEM Bench Engineer, OEM ......

Tarek Lahdhiri, PhD, PE, PMP, BB-DFSS, SM-IEEE

Introduction to Design for Sigma

Developed By

T. Lahdhiri, PhD, PE, PMP, BB-DFSS


Introduction Sigma and Design for Six Sigma


Measuring Quality - Sigma

Quality: is the degree of

completeness and perfection of a

product, process or service from the

customer’s viewpoint

Defect: If the outcome is too far from

the target value, then a defect occurs

Standard deviation (σ), is a measure

of variation from the target

Sigma Level, Z, of a process is:

(Spec Limit - Target) Z = Std Dev σ

Sigma Level measures the probability

of achieving a defect-free outcome

Target

Upper Spec Limit

Lower Spec Limit

s Defects Defects

3s

Sigma Level = 3


Definition:

The Sigma Capability of a process compares the Process performance

with respect to the customer specifications.

It is correlated to the defect rate and the complexity of the

process/product.

Objective:

Fit the product performance curve within the lower and upper specification

What is Six Sigma?


Benefits of Six Sigma

With six sigma, the process FITS well within the specifications, so even if the process

shifts, the values fall well within tolerances


What is Design for Six Sigma

DFSS is a design process

DFSS is or not necessarily a statistical process as it

sounds

DFSS is fundamental, good engineering.

DFSS is Structured, data-driven problem-solving

methodology

DFSS insists on evidence to support decisions.

“Show me” are the DFSS main arguments


Why Design for Six Sigma

DFSS supports making decisions where Data is the driving force

– quickly and efficiently (cost & time)

– that add value (benefit)

– while balancing risk

Cause of Defects

30% Manufacturing

70% Design

Methodologies used for problem solving

5% - Intuition

45% - Brainstorming

45% - Basic chart and Statistical Analysis

5% - Inferential Statistics


DFSS Process

Identify

Define

Design Improve

Test

Define requirements

Define measures

Define opportunities

for enhancements

Identify objectives

Identify customers

Identify team

Develop a plan

Develop concepts

Evaluate concepts

Select the appropriate concept

Verify product performance

Verify Process performance

Identify opportunities for

enhancements

Improve by identifying root

causes


DFSS Identify Phase

Objective: Develop a Plan


5 W’s Questions

5 W’s Questions

Why: Define value for customers

What: Define scope and objectives

When: Define milestones, deliverables, and timeline

Who: Create a team and responsibility chart

Where: Define location

The goal is to develop a plan for a robust design


Scope and Objective

Define the objective of the project

Example: Create a software package to automate the

execution of test cases on the bench for Electronic

Control Units (ECUs)

Define current practices

Define scope/boundaries:

Use diagrams to define what is-cope and what is out of

scope


Example: Bench Automation Project

Specifications

Interfaces

Scripting Automation Software

Simulation Instrumentation

Bench Report


Team

Identify everyone on the core team

Their functional department

Their general role on the project

Their contact information

Create a roles list and responsibility matrix

Clarifying and communication tools

Critical for elucidating cross-functional responsibilities

Do early and update as more is known

Keep the team list visible


Team Roles List

TEAM

Members Assignment Phone/e-mail

OEM Project Owner, OEM Project Owner: Budget approval +

Group manager

967-555-0292,

[email protected]

OEM Project Manager, OEM

Project Manager: Business Case +

Requirements + UATs + Supplier

management + Technical reviews

967-555-2398,

[email protected]

OEM Project Champion, OEM Project Champion: Techincal reviews +

Product testing and evaluation

967-555-0476,

[email protected]

OEM Bench Engineer, OEM Bench Engineer: Bench Application and

setup + Product Integration

967-555-3211,

[email protected]

OEM Model Engineer, OEM Model Engineer: Provide test vectors

and modeling support

967-555-2952,

[email protected]

OEM Application Engineer, OEM Application Engineer: User Acceptance

Test and HW platform support

967-555-2952,

[email protected]

OEM IT Representative, OEM

IT Coordinator: System integration

within the corporate network and

deployment

967-555-1312,

[email protected]

OEM Purchasing Representative, OEM Purchasing Coordinator: SOW + PO +

Payments

967-555-2323,

[email protected]

Supplier Team Leader, Supplier

Supplier PM, Supplier

Supplier Engineer-01, Supplier

Supplier Engineer-02, Supplier

Supplier: Develop and deploy the

Automation Tool

932-555-1300, Ext 232,

[email protected]

932-555-1300, Ext 249,

[email protected]

932-555-1300, Ext 289,

[email protected]

932-555-1300, Ext 272,

[email protected]


Scheduling/Estimating Steps

Create a work breakdown structure

Estimate work to complete the tasks

Identify dependencies among tasks

Assign resources to tasks

Identify critical issues to track

Include contingency plans

Identify milestones to track


Project Timeline

Set up “tools” for tracking

Schedule software if desired

Project Vision

Milestone lists

Critical issues list

Action items, key decisions

Design review checklists

Testing and defect goals, tracking mechanisms

Keep these “tools” visible to the team


Milestones

MILESTONES

Milestones Description Target

Date Status

1. Project Initiation Project Kick-off meeting + Defining milestone, diliverables,

and project timeline 1/7/2011 Completed 01/11/11

2. Work break down

structure

Supplier to provide the work break down structure and a

high level design document 2/1/2011

Completed 02/01/11,

Approved by PM

3. Design Document Supplier to provide all input required to generate the

Design Document required for the Toll-Gate 2/18/2011

Completed 02/21/11,

Approved (TG, 3/1/11)

4. Toll Gate OEM Project Manager to go through an internal Toll Gate 3/1/2011 Completed 09/01/11

(Design Approved)

5. Data Type Definition Supplier to provide the XML DTDs 3/21/2011 Completed 09/21/11

6. Alpha release Supplier to provide the Alpha release + Demo 5/1/2011 Completed 09/01/11

Approved by (PM, PC)

7. Beta release Supplier to provide the Beta release + Demo 6/1/2011 Completed 06/30/11

Approved (PM & PC)

8. Pre-Production Release Supplier to provide the Pre-production release + Demo 7/15/2011 Completed 09/15/11

Approved (PM & PC)

9. OEM Feedback to

Supplier GM to provide fedback about the pre-production release 7/31/2011 Completed 09/01/11

10. Final release Supplier to provide the Final release + Demo 8/15/2011 Completed 10/15/11

Approved (PM & PC)

11. UATs +

Documentation Finalize User Acceptance Tests + final documentation 9/1/2011 Completed 11/06/11

12. Sign-off + Project

Closing Approve the product and close the project 9/7/2011 Completed 11/11/11


Deliverables

DELIVERABLES

Deliverables Description Target

Date Status

Work Breakdown Structure Detailed work breakdown structure 2/1/2011 Completed 02/01/11,

Approved by PM

High level Design

Document High level design document 2/1/2011

Completed 02/01/11,

Approved by PM

Detailed Design Document Final design document required for OEM

Internal Toll-Gate 2/18/2011

Completed 02/21/11,

Approved (TG, 3/1/11)

Alpha SW Release Alpha Software: Functional software 5/1/2011 Completed 09/01/11

Approved by (PM, PC)

Beta SW Release Beta Software and Initial System/User

Documentation 6/1/2011

Completed 06/30/11

Approved (PM & PC)

Final SW Release Final release and System/User Documentation

and Pre Deployment Demo 8/15/2011

Completed 10/15/11

Approved (PM & PC)

Closing the project UATs + sign-off 9/7/2011 Completed 11/11/11


DFSS Define Phase

Objective: Define requirements


Customers

Identify your customer

Get input and understand the customer needs

Define value for the customer

Increase efficiency

Consistency

Speed of delivery

Eliminate waste

Reduce cost without reducing performance

Increase market share


Define your System

Identify the inputs and outputs of the system

Understand the functionality of the system

Define the system’s function

Y = F(X)

Example: Temperature Regulation System

System Description

Function F(.)

Inputs

X1, X2, X3

Outputs

Heat Vent Cooling (HVC)

System

Temperature

Humidity

HVC Controls

Y1, Y2, Y3


Requirements Functional Requirement

Functional Behavior Data Performance Interfaces

Non-Functional Requirements

Usability Training Security Operating system and CM

Tool Requirements

Testing setup Testing tools

• Gather all specifications to define the best project requirements

• Discuss the requirements with customers and do not interpret

them on your own way


Translating Requirements into Functional Measures

It is not always obvious how to translate the requirements

and customer needs.

Customers do not use engineering terms.

Customers convey their perceptions in their own terms

(e.g. fast, reliable, friendly, etc...)

Be careful not to jump to the wrong conclusion based on

the voice of customers.

Define functional measures to translate the requirements


Developing Functional Measures

Use rigorous methods to develop evidence

Hypothesis

•Use your understanding of the system and expertise to come up with a functional measure

Test

•Test the hypothesis and collect data

Conclusion

•Analyze data against hypothesis

•Make decision about adopting the hypothesis


DFSS Design Phase

Objective: Create the best concept


Current Practices

Identify the current methodologies being used

Example: Testing of Vehicle Electronic Control Units

- in-vehicle testing

- Manual testing in the lab

Gather data for all existing methods and processes

Example:

- How long does it to perform the complete test suite

- Equipment and instrumentation needed

- Cost

- Reusability

Use visual methods (graphs) to analyze data

Define opportunities for enhancements


Develop Concepts

You can start with existing concepts

Develop concept alternatives

Compare and contrast alternatives: Benchmark.

Use your understanding of the contrasts to develop better

concepts

Use the data to select the best concept for your

application and not to defend any concept

The best concept may not be in your concept list


Select The Best Concept

Select the best concept for your application

Method: Use the Pugh Concept developed by Dr. Stewart

Pugh from the University of Strathclyde, Glasgow, Scottland

This method is based on establishing selection criteria

Criteria should be measurable

You may need to rank the criteria (priority)

Use data to compare criteria and not personal judjment


Pugh Matrix Score:

S: Same

Co

ncep

t 1

Co

nc

ep

t 2

Co

ncep

t 3

+: stregth

-: Wekness

Criteria Priority Concept 0

Functional/Performance Criteria

D

A

T

U

M

- Function of the concept

- Performance Requirements

- Additional functional Criteria identified

Non functional Criteria

- Cost

- Time

- Risk

Score

- Sum of "+"

- Sum of "-"

- Sum of "S"


Sample of Pugh Matrix & Interpretation

Score:

S: Same

Co

ncep

t 1

Co

ncep

t 2

Co

ncep

t 3

+: stregth

-: Wekness

Criteria Priority Concept 0

Functional/Performance Criteria

D

A

T

U

M

- Function of the concept - S +

- Performance Requirements S S +

- Additional functional Criteria identified S S +

Non functional Criteria

- Cost + + S

- Time + S -

- Risk S S -

Score

- Sum of "+" 2 1 3

- Sum of "-" 1 0 2

- Sum of "S" 3 5 1

Less expensive and Fast

Does not add any value

to customer Less expensive

Does not add any value

to customer

Best for customer

Has risk and timing

issues

Best Solution:

Concept 4 = Hybrid of Concept 2 and 3


DFSS Improve Phase

Objective: Optimize the Design and Improve the robustness


Optimize Design

We have already defined the functional measures that drive

customer satisfaction. This is the starting point of this phase

Question: Can we develop better criteria?

Answer: YES, better understanding of the customer needs

and using physics thinking

Example: Generator

Requirements

The customer focus is on the energy (electric energy)

This may lead to different design and selection

Generator Speed (RPM) Current

Generator Mechanical W

W = Tq*RPM

Electric W

W= V*I


Improve Robustness

Robustness is a measure of the design sensitivity to noise factors

Noises are undesired functions of the system or external factors acting on

the system

Examples:

Digitization of signals introduces quantization noise (noise created by

the process it self)

Temperature may affect the overall system behavior for a sensor

(external factor)

Noise factors have an effect on measurements (e.g. vibration).

Robust design involves deciding on the best values and/or levels for the

control factors in the presence of noise factors.


Parameter Diagram (P-Diagram) The P-Diagram relates the inputs to desired outputs of a design that the

engineer is creating.

Also it takes into consideration non-controllable outside influences.

P-Diagram with an example (Generator)

Control Factor • Power Rating • Type • Size

Outputs Electrical Energy

Noise Factors Temperature

System

Generator

Inputs Mechanical Energy

Symptoms Magnetic noise

Aerodynamic noise


DFSS Test Phase

Objective: Verify that the design meets requirements


Test and Verify

Develop a test plan

Implement the solution and test the product

Collect data

Analyze data

Verify that the product works as expected

Prove that all hypothesis are correct

Verify that product meets requirements

The key success in this phase is to define Use Cases


Use Cases

Create use cases to test the product vs. requirements

Use Case ID: Requirement-2013-UC-R.1.1 Script Generation – Load Project

Use Case Name: Script Generation – Load Project Version No: Final

End Objective: Load all script files from previous session.

Created by: Bench Engineer On (date): 01/22/2013

Last Update by: Bench Engineer On (date): 01/29/2013

Approved by: PM On (date): 01/29/2013

Business Owner

Name:

Manager Contact

Details:

[email protected]

Trigger: “Script Generation – Load Project”

Frequency of Use: N/A

Basic Flow

Step User Actions System Actions

1 The Engineer selected “Load

Project”

The associated script generation files for the

selected project are loaded.

Each requirement should be mapped to a use case


DFSS Closing and Concluding Remarks


Finalizing the Project

Closing the Project All phases are completed All critical issues are addressed Product is approved by customer Advertise your accomplishment:

Documentation Complete and approve all documents related to the

project Lessons Learned

Conduct a lesson learned session Document what went good and wrong What can be done better in the future


Concluding Remarks

Evolving and continuously

changing design requirement

Extensive and expensive design

rework

Performance and robustness is

assessed by build and test

Flaws discovered after putting

the product in use

Quality “tested in”

DFSS is a design process that change a traditional Reactive

Design Process into a Predictive Design Process

Disciplined flow down and

requirement development

Controlled design parameters

Data driven solution

Robust design to minimize

changes for flaws

Quality is “designed in”

DFSS


IT’S TIME FOR QUESTIONS


Thank you for your time.

Contact Information: Tarek Lahdhiri

Email: [email protected]

mailto:lahdhiri@

Introduction to Design for Sigma Developed By Toolkits/The DFSS... · OEM Bench Engineer, OEM ......

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