design for six sigma overview

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Intro to the DFSS methodology.

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  • 1. Design For Six Sigma Travis Eck

2. Selection 3. Outline

  • Tools for Design
  • Design
  • Design failure mode
  • Effect analysis
  • Reliability Prediction
  • Design Development
  • The Taguchi loss function
  • Optimizing Reliability
  • Design Verification
  • Reliability testing
  • Measurement system evaluation
  • Process capability Evaluation
  • Tools for Process Improvement
  • Basic tools
  • Flow Charts
  • Run Charts
  • Control Charts
  • Check Sheets
  • Histograms
  • Pareto Diagrams
  • Cause and Effect Diagrams
  • Scatter Diagrams
  • Other tools
  • Kaizen Blitz
  • Poka-Yoke
  • Process simulation
  • Engaging the Workforce
  • Improvement
  • Skills for team leaders
  • Skills for team members

4. Tools for Design

  • Design failure Mode and effect analysis (DFMEA)
  • Design-FMEAs should be used throughout the design process - from the preliminary design to when the product goes into production. Design-FMEAs uncover potential failures associated with the product that could cause product malfunctions, shortened product life, and safety hazards to name a few.

5. Tools for Design

  • Reliability Prediction
  • The ability to perform over time
  • Numerical measurement between 0-1
  • Functional failure
  • Reliability failure

6. Tools for Design Development

  • The Taguchi loss function
  • "a minimal loss at the nominal value, and an ever-increasing loss with departure either way from the nominal value." - W. Edwards Deming Out of the Crisis. p.141
  • Measuring loss
  • Keeps focus
  • keep product and process as close to the nominal value as possible

7. Tools for Design Development

  • Optimizing Reliability
  • Crucial Steps: Assess process capabilities to achieve critical design parameters and meet CTQ limits
  • Optimize design to minimize sensitivity of CTQs to process parameters
  • Design for robust performance and reliability
  • Error proofing
  • Establish statistical tolerance
  • Optimize sigma and cost
  • Commission and startup

8. Tools for Design Verification

  • Reliability Testing
  • Life testing
  • Accelerated life testing
  • Component Stress testing
  • Metrology
  • Accuracy
  • Precision
  • Repeatability

9. Tools for Design Verification 10. Tools for Design Verification

  • Process Capability Evaluation
  • Where is the process centered?
  • How much variability exists in the process?
  • Is the performance relative to specifications acceptable?
  • What proportion of output will be expected to meet expectations?
  • What factors contribute to variability?

11. Tools for Process Improvement 12. Tools for Process Improvement 13.

  • Flow and Run Charts
  • Easy to use
  • Clear Communications
  • Identifies areas of opportunities
  • Familiar in the business world
  • Great for comparing data
  • Good for project identifications

Basic Tools 14.

  • Control Charts
  • Identify variations
  • Predict when process is out of control
  • Anticipates change
  • Tells a story
  • Check Sheets
  • Provide clarity of ideas
  • Useful in keep discussions ideas on target
  • Quickly created
  • Easily reorganized

Basic Tools 15.

  • Histograms
  • Prioritizes opportunities
  • Provides base for projects
  • Recognizable
  • Pareto Diagrams
  • Prioritize work
  • Principle that 80% of deviations are caused by 20% of the process

Basic Tools Daily Inspections 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 0.00- 0.72 0.72- 1.44 1.44- 2.17 2.17- 2.89 2.89- 3.61 3.61- 4.33 4.33- 5.05 5.05- 5.77 5.77- 6.50 6.50- 7.22 Business Days Counts 16.

  • Cause and Effect Diagrams
  • Also known as the 5 whys
  • Root Cause Analysis
  • Structures thoughts
  • Keeps group on track
  • Directs improvements to the right areas

Basic Tools 17. Group Activity 18.

  • Scatter Diagrams
  • Help define the correlation between characteristics
  • Indicate a cause and effect relationship

Basic Tools 19.

  • Kaizen Blitz
  • Poka-Yoke
  • "The causes of defects lie in worker errors, and defects are the results of neglecting those errors. It follows that mistakes will not turn into defects if worker errors are discovered and eliminated beforehandShingo 1986, p.50
  • Process Simulation

Other Tools 20.

  • Change the culture to an improvement focus group
  • Develop programs that encourage and develop the right skills for team leaders
  • Develop training and communication that provide additional skills to all team members

Engaging the workforce 21. Questions?