Lean Design For Six Sigma at Tyco Lean Design For Six Sigma at Tyco
Engineered Products & ServicesEngineered Products & Services
Ajoy BasuAjoy Basu
22
HealthcareHealthcare
ElectronicsElectronics
Fire & Fire &
SecuritySecurity
Plastics & Plastics &
AdhesivesAdhesives
Engineered Products & ServicesEngineered Products & Services
Flow Flow
ControlControl
Fire & Fire &
BuildingBuilding
Electrical & Electrical &
MetalMetal
Thermal Thermal
ControlsControls
Infrastructure Infrastructure
& Services& Services
$40 Billion$40 Billion
220,000 Employees220,000 Employees
33
Eliminate
Waste
Reduce
Variation
LeanLeanSix SigmaSix Sigma
Innovate
& GrowDFSSDFSS
Top Line
Bottom LineLean
Six Sigma
New Products – DFSS + ???
Product Extension – VOC + DFSS
A Holistic A Holistic ApproachApproach
44
33
4.54.5
66
Why DFSS?Why DFSS?
55
0
New
IdeasPreliminary
Investigation
Preliminary
Design
Final
DesignLaunch
1 2 3 4
New Product Development New Product Development ProcessProcess
Concept
Design Optimize Verify
Technology
Development
66
Gate 0: NPV Gate 0: NPV AnalysisAnalysis
Uncertainties fed into Analysis
77
Gate 0: Technology Gate 0: Technology GapGap
Time
Per
form
ance
Par
amet
er
88
Gate 1: Psychological Gate 1: Psychological InertiaInertia
99
Gate 2: Gate 2: LeanLeanWIP = CT * TP
1010
Lean AnalysisLean Analysis
1111
Cu
sto
me
r W
an
ts
Design Features
House of Quality
De
sig
n F
ea
ture
s
Parts Characteristics
House of Product Design
Pa
rts
C
ha
rac
teri
sti
cs
Process Operations
House of Process Planning
Pro
ce
ss
O
pe
rati
on
s
Process Parameters
House of Production Planning
PERFORMANCEPERFORMANCESCORECARDSCORECARD
PARTSPARTSSCORECARDSCORECARD
PROCESSPROCESSSCORECARDSCORECARD
Gate 3: Gate 3: ScorecardsScorecards
1212
PerformancePerformance
ScorecardScorecard
Process ScorecardProcess Scorecard
Lean ScorecardLean Scorecard
System System ScorecardScorecard
SoftwareSoftware
ScorecardScorecard
PartsParts
ScorecardScorecard
Robustness to manufacturing
variation?
Manufacturing capability of design?
Quality level of components?
Software Quality?
ReliabilityReliability
ScorecardScorecard
Design Reliability?
Critical Parameter ManagementCritical Parameter Management
1313
CPM in PracticeCPM in Practice
ComponentComponent PerformancePerformance ProcessProcess ReliabilityReliability
Part APart A 3.243.24 0.530.53
Part BPart B 3.133.13 6.186.18
Part CPart C 3.513.51 2.802.80 2.512.51
Part DPart D 4.904.90 4.504.50
Part EPart E 4.724.72 2.402.40
CumulativeCumulative 3.463.46 3.023.02 1.931.93
Parts
Scorecard
1414
Gate 4: Gate 4: ReliabilityReliability
1515
DFSS Rollout DFSS Rollout PlanPlan
Success FactorsSuccess Factors
1)1) Develop integrated NPD - DFSS processDevelop integrated NPD - DFSS process
2)2) Close gap regarding VOC, VOMClose gap regarding VOC, VOM
3)3) Candidate selected for DFSS MBB career pathCandidate selected for DFSS MBB career path
4)4) Select projects early in design cycle (within 6 months)Select projects early in design cycle (within 6 months)
5)5) Diligent and rigorous toll gate reviewsDiligent and rigorous toll gate reviews
6)6) Attentive portfolio managementAttentive portfolio management
1616
DFSS Roadmap - DFSS Roadmap - AA
DEFINE
D1 Needs analysis Market & Portfolio analysis, technology
forecasting
D2 Feasibility analysis Technical feasibility & financial viability
analysisCONCEPT
C1 VOC KJ image, QFD, Performance Scorecard
C2 Concept generation & selection TRIZ, Pugh
C3 Project charter
DESIGN
D1 Platform Architecture / Modular design
D2 Lean process analysis VSM, Takt time, Cycle time analysis
D3 DFM / A Lean scorecard (Boothroyd-Dewhurst)
D4 Design scorecard Sub System Scorecard
1717
DFSS Roadmap - DFSS Roadmap - BB
OPTIMIZE
O1 Identify Significant Xs MSA, DFMEA, C&E, Hypothesis testing
O2 Develop transfer functions DOE, RSM, robust Design, Y = f(x)
O3 Design optimization Simulation, Minimize complexity, Maximize
Robustness
VERIFY
V1 Prototype / Pilot Verify Capability
V2 Reliability Analysis
V3 Launch Control plans
1818
Project DatabaseProject Database
1919
CertificationCertification
1. 200 hrs of class room instruction
2. 80+% score in DFSS exam
3. 1 Platform level project or
2 Platform extensions
(no $ value for DFSS projects)
2020
Measuring DFSS Measuring DFSS SuccessSuccess
1. Vitality Index
2. Profit / Engineering $
3. Say / Do ratio
Top Related