what is dfss
DESCRIPTION
What is DFSS-Design for six sigma?TRANSCRIPT
Design for Six Sigma DFSS OVERVIEW
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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
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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
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Generic Business Model
PRODUCT INTRODUCTION PROCESS
SupportProcesses
INFORMATIONACQUISITION
PRODUCTION DISTRIBUTION
OPERATIONS PROCESS
MarketCustomers
Customers CustomersMAHESH
BRAMHA
VISHNU
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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
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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
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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
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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
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Opportunity For change
Difficulty to change
High
Low
Concept Prototype Pilot Production Customer
Why DFSS+Lean?
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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
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1980 1985 1990 1995 2000Survey Year
Consumer Reports
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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
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DesignProcess
ProjectManagement
BusinessManagement
Subject-MatterExpertise
DFSS
Source: Stuart Arnold, DERA Systems Engineering Reference Manual
Organizational Responsibility Profiles
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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
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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?
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When to use DFSS+Lean?
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Traditional linear approach
Simultaneous Engg. approach
Phases in No 1
Overlap Approach
DFSS Philosophy of Concurrent Approach
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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
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“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
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What is IDOV Methodology?
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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
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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
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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
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Tools
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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
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Customer Domain
FunctionalDomain
ProductDomain
ProcessDomain
QFD
CTQ Scorecard Concept
DFM
DFA
Optimized Product Design
Lean
DOE
DFSS Process Flow
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Design Steps
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Design Procedure
Optimize Phase Overview
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Optimize Steps
Verify Phase Overview
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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
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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
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Thank You