sustaining dfss… keeping up the momentum
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MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
Tom JuddSr. Director, Product Development Quality
Master Black Belt, SSPDCorporate Quality Office
Sustaining DFSS…Sustaining DFSS…Keeping Up the Momentum Keeping Up the Momentum
Design For Six Sigma 2007April 3-4, Chicago
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
2
“Motorola’s vision of Seamless Mobility means people have easy, uninterruptedaccess to information, entertainment, communication monitoring and control.”
Total 2006 Revenue => $42.9 Billion
By Region
NorthAmerica
Europe
LatinAmerica
AsiaRegion
China
Others
MobilDevices
Networks &Enterprise
Connected Home Solutions
By Business
** Source: Motorola 2006 Annual Report
MOTOROLA
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
3
MOTOSLVR
MOTOKRZR
MOTOROLA Q
MOTOPEBL
Mobile Devices Business
Global Leader in the Personal Communications Industry
MOTORIZR
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
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"July 7 has brought home more than ever the need for trusted, resilient and reliable emergency communications...one technology, one open standard.” Pete Richardson02 Airwave
“Our 800 MHz trunked critical communications network was the only game in town …From the storm’s landfall through today, it provided the foundation for all communications.”
Paul Winter Charlotte County, FL
2006 London Bombings
2004 Florida Hurricanes
Networks & Enterprise Business
The Global Leader in Government & Commercial Communications Systems
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
5
Global leader in broadband Connected Home solutions and services, seamlessly enabling customers to be
informed, connected and entertained.
Connected Home Solutions Business
Digital Video & VOIP Solutions
AdvancedWirelessSolutions
Next GenerationHome Communication
Solutions
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
6
Six Sigma Product Development at MotorolaSix Sigma Product Development at Motorola
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
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Technology Strategy
Product Portfolio Product Portfolio Definition & Definition &
Development Development
Product Portfolio Product Portfolio Definition & Definition &
Development Development
P2D2
II DD EE AA
Business Strategy
Marketing Strategy
Technology & Technology & Software Platform Software Platform
Development Development
Technology & Technology & Software Platform Software Platform
Development Development
SWDFSS
RR DD CC VV
TDFSS
II22 DD OO VV
HW/SW DFSSDD OO VVCC
MFSS
CC DD OO VV
Product Product CommercializationCommercialization
Product Product CommercializationCommercialization
ProductLaunch
Six Sigma for Product Development (SSPD)*
* Based on SSPD Model by Skip Creveling, PDSS
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
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Establish CentralSSPD Team
Internalize HDFSS TrainingDevelop GBs & BBs
Create “Point Solution” HDFSS Projects
Map SSPD tothe NPI Process
Expand Application ofSSPD on NPI Programs
Meld SSPD with OtherNPI Processes & Groups
No More “SSPD”…No More “SSPD”…Just the way we do NPIJust the way we do NPI
SSPD Spiral of Maturity
Initial HDFSS Training by Outside Consultants
Modularize Training andCommunications Plan
Limited Application of SSPD at the Program Level
Influence ManagementTo Give SSPD a Shot
Launch Additional SSPD Disciplines
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
9
SSPD Management Organization
SSPD Process/Methods Consulting SME Resource for Training Material Set SSPD Program Success Metrics Belt Training & Certification Program SSPD Infrastructure Development SSPD Communications Plan
Responsibility to Businesses:
Establish a Lead SSPD MBB Map SSPD to M-Gate Process Identify SSPD Belt Candidates Select SSPD Programs/Projects
Businesses Responsibilities:
Mobil DevicesBusiness
Networks & EnterpriseBusiness
Connected HomeSolutions Business
Corporate Quality Office
SSPD Team
Sponsored by CQO SSPD Technical Experts Training & Consulting Experience Change Management Savvy
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
10
Yields Positive, but Limited Success for SSPD Deployment…. Belt Projects prove Benefits & Effectiveness of Tools Develops DFSS Belts within the Organization Develops Limited “Pull” from Program Management Begins to Develop Commons Language Identifies Potential DFSS Leaders within Organization
No Real Cultural Change at the NPI Program Level
Laying the SSPD Foundation – HDFSS
QFD
FMEA
DOE
Y=f(X)
Statistics
STA MSA
DFx
Discrete “Smoke Stacks” of HDFSS Tools Deployed to Projects……
Initial “Belt” Wave Training (by Consultants) Yields:
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
11
Motorola “Point Solution” Successes
Mobile Voice & HighSpeed Data Unit
Y = Block Error Rate
Saved 4 Weeks of Testing!
Mobil Voice T/R Unit
Y = Increase Frequency
Skipped the Pilot Build Phase!
UBS1.02 Weekly Fault Arrival by Inroduced in Phase
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Implementation
Design
Requirements
Cellular Base Station Unit
Y = Reduce Software Fault Rate via FMEA
Significantly Discovered &Mitigated Software FaultsPrior to Acceptance Testing!
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
12
Influencing Management on SSPD
It’s All About Doing Things Right the First Time…..
As the Carpenter says……
Determine the necessary length of the board…
Collect VOCs Understand Requirements
Measure Twice…..
Cut Once…
Identify & Reduce Risks
Right the First Time!
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
13
Need to Change the Product Development Culture
Replace the “Fire Fighting” Program Management Culture……
With a “Fire Prevention” Program Management Culture….
Test in Quality
Design in Quality
Influencing Management on SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
14
Shift Resources for Proactive, Predictive Product Development
Stress that SSPD NPI Resources <= Typical NPI Resources
NP
I Res
ou
rce
Lev
el
NPI Development Time Launch
Typical Resource Profile
Resource ProfileUsing SSPD
Post Launch“Fire Fighting”Can always find
Resourcesfor This
Shift Resources“Up Front” to Find & Mitigate
Risks Early
Influencing Management on SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
15
Up Front “Discovery Sessions” Lead to Identifying Risks andDiscovering Opportunities Early in the Development Cycle
Radar Project
Facilitation Meetings Maintain a System Level Perspective During
Development with Constant Focus on Customer & Business Needs
Enables Cross Function Perspectives that Discover Interactions & Constraints
Provides a Forum for “Out of the Box” Thinking That Leads to
New Idea Generation
Cross Functional
Team Members
(Engineering, Test,
Quality, Mfg, SMEs)
DiscoveryDiscoverySessionsSessions
Influencing Management on SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
16
Discovery Sessions set the Stage for the Analytical Tools
Critical Parameter Management & DFMEA……Proven Methods/Tools to Capture Product “Tribal Knowledge”
Radar Project
Critical Parameter Management (CPM)is Applied to “Proactive” Requirements
EX: “How do we achieve the required range?
System
SubsystemSubsystem
VendorComp Comp Mat’l
DFMEA is Applied to “Reactive” Requirements
EX: How do we make this water proof?
Influencing Management on SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
17
Total Product Level Requirements
Performance & Functional Requirements
New-Unique-Difficult (NUD) Requirements
Top Critical NUD Requirements
““Keep You Up At Night”Keep You Up At Night”NUD RequirementsNUD Requirements
Let’s not “Boil the Ocean”Let’s not “Boil the Ocean”
Limited Application of SSPD
System Requirements Management
“Tribal Knowledge”Filtering
Traced to NUD VOCsvia House of Quality
Apply DMEA & CPMFlow Down Methodto Find Contributors
Develop & ExerciseTransfer FunctionsTo Mitigate Risks
Methods & Tools
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
18
Structure to Support the System Level Approach to DFSS
DFSS PROGRAM (ex: Complete Phone)
DFSS PROJECT
Black Belt Program
Green BeltProject
DFSS PROJECT
DFSS ToolApplicationIndividual
Contributor
DFSS PROJECT
DFSS ToolApplication
DFSS ToolApplication
DFSS ToolApplication
Limited Application of SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
19
Success Stories beyond “Point Solutions”
Risk: Several System Level Critical Parameters(Color Display Characteristics, Button Tactile Feel, Spurious Emissions, Power Supply Emissions, Water Intrusion, Audio Quality)
Success Statement:
Eliminated 13 Design Iterations (2-4 Iterations spread among several individual GB level projects)
Reduced Design Cycle Time by 27 Weeks Met All Design Specs with Significant Margins (>5%-85%) Passed FCC Requirements with NO Issues Customers stated, “Motorola listened and responded” At the 2006 APCO Convention, Customers raved about the ’look and feel’ of the (product)”
Limited Application of SSPD
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
20
Limited Application of SSPD
Risks Mitigated by DFSS are Like “Beams of Light” PiercingThrough the Storm of all the Other Product Launch Problems
This “Turns the Heads” of Program, Functional & Business Management
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
21
“Inbound” Marketing for Six Sigma (MFSS)
Technology Development for Six Sigma (TDFSS)
Product Portfolio Definition &
Development
DMADV Six Sigma (Issue Resolution)
Hardware Design for Six Sigma (HDFSS)Software Design for Six Sigma (SDFSS)
“Outbound” Marketing for Six Sigma (MFSS)
Business CaseBusiness CaseDevelopmentDevelopment
PortfolioPortfolioPlanningPlanning
ProjectProjectDefinitionDefinition ImplementationImplementation Launch &Launch &
CloseoutCloseout
Motorola Product Development Gate Governance
SSPD Mapped to the M-Gates
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
22
Methods & Tools Mapped to PDP Process
Business CaseBusiness CaseDevelopmentDevelopment
PortfolioPortfolioPlanningPlanning
ProjectProjectDefinitionDefinition ImplementImplement
Voiceof
Customers FocusGroups
Gemba
Interviews
Ethnography
CPM
Pugh
DFMEA
DesignSpecsQFDKJ
Surveys
(Consumers,Carriers,Business,
Technology)
TransferFunctions
DOE’s
RSM
ReliabilityAnalysis
MSA
Kano
Marketing - MFSSMarketing - MFSS Engineering – HW & SW DFSSEngineering – HW & SW DFSS
MrktgMrktgToTo
EngEngHandHandOffOff
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
23
Plus…. Advanced Technical Subject Matter Training Where Needed
Migrate to Modularized Training
Training Synchronizedwith the DFSS Steps
Concept Define &Identify
Design Optimize Validate
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
24
Target Groups Com
mitm
ent (
$, R
esou
rces
)
Ow
ners
hip
Buy
-In
(Pul
l, Se
ll)
Dev
. Par
ticip
atio
n (P
artn
er)
Adv
ocat
e
Imp.
Par
ticip
atio
n (R
oll-
out)
Ben
efits
Impa
ct/E
ffec
t
Proj
ect S
tatu
s
Les
sons
Lea
rned
Vis
ion
of S
ucce
ss
Key
Suc
cess
Fac
tors
Wha
t is
D.I
.?
Act
ion
Item
s
Mode of Communication
President & Staff M H T T T T T T T T Quarterly Presentations
VP Eng, Mfg, Mktg, 6S H H H O O O O T O O O Mtgs Monthy & As Req'd, E-mails
DFSS Project Champion(s) H M H H M T D D D O D O D Mtgs Weeky & As Req'd, E-mails
Enginering Program Mgrs M H L H M O O O O O O O D Monthly Presentations
Stake Holders (Mft, Ops, QA) M M M M T O O O T O T O Monthly Presentations
DFSS Pilot Project Team Mgrs L H M H H O D O D D T D D Mtgs Weeky & As Req'd, E-mails
DFSS Project Team Members H M L H O D O D D T D D Mtgs Monthy & As Req'd, E-mails
Other Eng. Project Teams H O O T O O T O Quarterly Presentations
DFSS Team M H H H D D D D D D D D Mtgs Weeky & As Req'd, E-mailsCorporate DFSS Team L L T T T T T T End of Pilot Project Presentation
DFSS Communication Plan
H = High, M =Medium, L = Low D = Detailed, O = Overview, T = Top Level
Importance Rating Communication Contents
Communication Plan
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
25
Launch Additional SSPD Disciplines
Start with HDFSS… Proven Methods/Tools Tangible Physics Quick Success Stories
HDFSS Deployment ModelServes as Baseline forSoftware DFSS and
Marketing for Six Sigma
Maturity of All ThreeDisciplines will begin
To Converge……
What Could Be Next??
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
26
System Requirements
SystemArchitecture
HardwareRequirements
HardwareArchitecture
SoftwareRequirements
SoftwareArchitecture
.. ..
Gather VOC’sGather VOC’s
KJ/KANO AnalysisKJ/KANO Analysis
House ofQuality
Tools with aTools with aSystems/ProductSystems/ProductLevel ApplicationLevel Application
Tools SpecificTools Specificto HW & SW to HW & SW ApplicationApplication
PughMatrix
PughMatrix
CPM & FMEAFlow Down
Tools SpecificTools Specificto Marketingto MarketingApplicationApplication
Launch Additional SSPD Disciplines
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
27
Expand Application of SSPD
The “Limited Application” Approach is Scaleable!!!
Meld SSPD with Other NPI Process & Groups
CMM/CMMI, Program Management, Business Ops, etc.
Testing, Supply Chain, Service, Purchasing, etc.
MOTOROLA and the Stylized M Logo are registered in the US Patent & Trademark Office.
All other product or service names are the property of their respective owners. © Motorola, Inc. 2005
2007 IQPC DFSS Conference2007 IQPC DFSS Conference
28
No More “SSPD”… No More “SSPD”… Just the way NPI is Done!Just the way NPI is Done!
The Utopian State
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