What Is Dfss

Design for Six Sigma DFSS OVERVIEW

passion for impossiblepassion for impossible

Objective

Objective of this session is to understand

What is DFSS?

Why to use DFSS?

When to use DFSS?

Differences between Six Sigma DMAIC and DFSS

2


Preamble

1. Design of a new process is more complex than running an operation (existing process)

2. Design involves cross functional involvement for success

3. Design is a project management & hence complex – eg Application devt.

4. Success of new product or a process is measured by Quality, Timeline and cost which is invariably not met.

5. It is wiser to design a six sigma product and process rather than improving after launch

6. As Process improvement needs DMAIC, new design needs DFSS


Generic Business Model

PRODUCT INTRODUCTION PROCESS

SupportProcesses

INFORMATIONACQUISITION

PRODUCTION DISTRIBUTION

OPERATIONS PROCESS

MarketCustomers

Customers CustomersMAHESH

BRAMHA

VISHNU


Issues faced in New Product or Service Development

• Product or Service Development Constraints– Subject to increasing global competition & less duration of

product life cycle– Rapid technology shifts and substitutes– Quality and product liability issues needs better products &

services.

Time to Market

Quality Complexity


Resources Required &Number ofModifications

Time

Revenuewith DFSS

Revenuew/o DFSS+Lean

RevenueGenerated

DFSS+Lean Vision:Predictive Design

Predictive Design

Launch

Pre-DFSS Reactive Design

Launch

Application of DFSS


Reducing Time and Cost to Market

• Early identification of important, critical aspects helps setting realistic targets...– leading to a more focused design

and development phase– dramatically reducing need for

design changes late in the project

100%50-60%

ProductPlanning

Design & Development

DesignChanges

Using DFSS

Conventional


8

Design Stage Production Stage Quality control (during operations)

Special cause: Sporadic spike

Chronic waste (an opportunity for Improvements)

Time

Cost

of p

oor q

ualit

y

Ope

ratio

ns s

tart

Lessons learnt

Quality improvement

Why this rejection?

Apply DFSS

DFSS ZONE

Juran’s Breakthrough Improvement


Opportunity For change

Difficulty to change

High

Low

Concept Prototype Pilot Production Customer

Why DFSS+Lean?


Source: Six Sigma, The Breakthrough Strategy Revolutionizing The World’s Top Corporations by Mikel Harry

5%

20%

15%

Labor

Material50%

5%

Overhead30%

CostInfluenceCostInfluence

ActualCostActualCost

5%

70%

Design

Impact of DFSS+Lean in Service design


1980 1985 1990 1995 2000Survey Year

Consumer Reports


Increase Sigma Levels• Typical new designs perform in the 2-3 Sigma Range

• Develop designs that can be produced on-target with minimum variation, operating at customer defined performance levels

USL

CTQ

Most Organizations Today

World Class Designs needs DFSS

LSL


DesignProcess

ProjectManagement

BusinessManagement

Subject-MatterExpertise

DFSS

Source: Stuart Arnold, DERA Systems Engineering Reference Manual

Organizational Responsibility Profiles


Design For Six Sigma

Pro

cess

Man

agem

ent

Six S

igma D

MA

IC

Process Management supports and maintains the projects’ solutions once they are fully implemented. It is a source for new improvement and design projects.

DMAICincrementally improves existing processes by systematically removing root causes for variation.

Design For Six Sigmais used when a new a product or service is needed or an existing requires significant change so that the improvement process is inadequate.

Three Dimensions of Six Sigma


OUTPUTCritical To Quality

Characteristics

REQUIREMENTS Stated

EXPECTATION Hassle free

transaction

NEEDS Implied

JOURNEY OF EXCELLENCE - DMAIC & DFSS

PROCESS

INPUTS

DO’s DefectOpportunities

Process Capability

Delighted

Happy

Dissatisfied

Customer

Re-design

ANALYZE , IMPROVE & CONTROL MEASURE DEFINE

Project yY = f (x1, x2 ,………….Xn)

VERIFY , OPTIMIZE , DESIGN , IDENTIFY

How Six Sigma Methodology Works?


When to use DFSS+Lean?


Traditional linear approach

Simultaneous Engg. approach

Phases in No 1

Overlap Approach

DFSS Philosophy of Concurrent Approach


Critical Business

Need?

Existing Product?

IncrementalImprovement

possible?

ProcessManagement

No

Yes

Yes

IDOVNo

IDOV

No

DMAIC

Yes

Define

Measure

Analyze

Implement

Does solution

require new product design?

Control

IDOV

Yes

No

IDOV vs. DMAIC


“We are going to Shift the Paradigm from fixing Products to fixing and Developing Processes, so that they Produce nothing but Perfection or Close to It!!” Jack Welch

DFSS+Lean


What is IDOV Methodology?


Identify Design Optimize Verify

To select the best product or service concept based on the voice of the customer (VOC)

To build a thorough base of knowledge about the product or service and develop the process

To develop a Robust design toachieve a balance of quality, cost, and time tomarket

Check the final Design to ensure that the product or service is meeting customerrequirements

Plan High level design Robust design Testing & production

IDOV Approach


Process capability

Problem solving techniques

Concept development

QFD

Design for manufacture (DFM)

Detailed product design

QFD

Product FMEA

Taguchi

DFM

Validation testing

SPCProduction

Quality function deployment (QFD)

Requirements definition

Production system concepts development

QFD

Process FMEA

simulation

Detailed process Design

QFD

Product FMEA

Taguchi

Poka yoke

Validation testing

simulation

DFSS Tool Kit

Identify Phase Overview


Identify Design Optimize Verify

To select the best product or service concept based on the voice of the customer (VOC)

To build a thorough base of knowledge about the product or service and develop the process

To develop a Robust design toachieve a balance of quality, cost, and time tomarket

Check the final Design to ensure that the product or service is meeting customerrequirements

Plan High level design Robust design Testing & production

We are here

IDOV Approach


Tools


Define Project Decide Strategy Identify Requirements

A well-defined charter and mission statement make sure the project is in the right track

Identify Factors Critical to SuccessFailure to recognize and address a significant risk could jeopardize a project.

Develop a Multi Generation PlanAn MGP helps you decide what needs to be done now and what should be done later

Develop Project PlansSpending time up-front working with others in the organization to integrate the project plan is well worth the effort.

Understand the Voice of the CustomerThe Voice of the Customer (VOC) describes customers’ needs and their perceptions of your product or service. Focusing on true customer benefit makes sure you are solving the right problem.

Translate VOC into Measurable CTQs

The QFD matrix is based on the VOC work to identify customer needs and priorities. A performance scorecard can be used at this stage to start tracking reliability

Identify Tools & Activities

Design Phase Overview


Customer Domain

FunctionalDomain

ProductDomain

ProcessDomain

QFD

CTQ Scorecard Concept

DFM

DFA

Optimized Product Design

Lean

DOE

DFSS Process Flow


Design Steps


Design Procedure

Optimize Phase Overview


Optimize Steps

Verify Phase Overview


Test & Pilot Verify & Validate Transfer / Close

The pilot sets the tone for full deployment. It helps think through the issues and set expectation for everyone

Prototype / PilotThe plan for collecting data during the pilot should be based on the Process Management Chart

Capability ValidationPrototyping and production ramp-up make extensive use of standard Six Sigma DMAIC tools to validate and verify manufacturability and fitness for use.

After completion of production, responsibility is transferred from the design team to the process owner.

Implementation and ClosureClosure documents and process deliverables are prepared. Project resources are released and redistributed.

An increased testing using formal tools occurs

Project Management Chart

Verify Tools & Activities


1/2 day

Team Formation

Identification Coaching

3 days2 days

Design Coaching

3 days

Optimize – VerifyCoaching

3 days

Design Documentation

Coaching

4 weeks 3 weeks

2 – 3 weeks1 1/2 days

2 days 3 weeks for data collection

3 days

DFSS Road Map for NSE

Kick off workshop & Project Brief

DFSS – I – Phase Training

DFSS – D – Phase Training

DFSS – OV – Phase Training


Thank You

What Is Dfss

Documents

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