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