DFSS, Innovation and I-TRIZ Tools

“Innovative Designs for Six Sigma”

DFSS, Innovation and I-TRIZ Tools

“Innovative Designs for Six Sigma”

BREAKTHROUGH IMPROVEMENT AND BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINSINNOVATIVE DESIGN ORIGINS

BREAKTHROUGH IMPROVEMENT AND BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINSINNOVATIVE DESIGN ORIGINS

Global Leaders in their fields

                  

Genrich Saulovich AltshullerFather of TRIZ

Dr. Joseph M. JuranFather of Breakthrough

Improvement

OUR CREDIBILITY AND OUR CREDIBILITY AND EXPERIENCEEXPERIENCE

OUR CREDIBILITY AND OUR CREDIBILITY AND EXPERIENCEEXPERIENCE

A 23-year successful Juran track record in achieving bottom-line results through pragmatic and systematic implementation of quality management and breakthrough methodologies for our clients.

The Juran-Ideation partnership creates from the strengths and capabilities of two industry leaders a synergistic offering of Innovation and Six Sigma Performance.

A proven, comprehensive business approach, “strategic and tactical” due to the depth and breadth of the full-time Juran Institute staff and services that are unsurpassed by our competitors.

Juran Institute DFSS training and consulting materials are experience-based, translated in multiple languages. Many of our materials are basic

references which are used by clients, universities and other consultants. The DFSS-TRIZ Integration is a unique offering in the industry.

Ideation established 1992Ideation established 1992

Merged with Kishinev School (Leading TRIZ School in Russia)Merged with Kishinev School (Leading TRIZ School in Russia)

Headquarters in Southfield, MI Headquarters in Southfield, MI

85% of the world’s leading TRIZ Scientists85% of the world’s leading TRIZ Scientists

Installed customer base of over 2,000 enterprises worldwideInstalled customer base of over 2,000 enterprises worldwide

Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers established worldwideestablished worldwide

IDEATION INTERNATIONAL INC.IDEATION INTERNATIONAL INC.

Ideation International is a world-class provider of accelerated education, innovation software tools,

and analytical services based upon the Ideation/TRIZ Methodology, to enterprises of all

types and sizes.

By understanding the mechanisms that create change, providing the means for recognizing how

to adjust to change, and bringing the essential benefits of innovation, creativity and knowledge to

enterprises, Ideation will achieve its mission.

IDEATION’S MISSIONIDEATION’S MISSION

WHAT IS IDEATION’S WHAT IS IDEATION’S

BUSINESS?BUSINESS?

Inventive Problem Solving

FailureAnalysis

FailurePredictionA

ntic

ipat

ory

Fail

ure

Det

erm

inat

ion

Education Software PublicationsAnalyticalServices

BooksPapers

BookPapers

54 yrs

22 yrs

22 yrs

12 yrsDirected

Evolution PapersUnder

Development

Provider of I-TRIZ:

Age of Application

JURAN INSTITUTE’S MISSIONJURAN INSTITUTE’S MISSION

Our mission is to provide Our mission is to provide professional consulting services to professional consulting services to

improve improve continuously continuously the performance the performance of our clients’ processes, products, of our clients’ processes, products,

people, and profitspeople, and profits..

JURAN INSTITUTEJURAN INSTITUTE

Founded 22 years ago by Dr. J. M. Juran.Founded 22 years ago by Dr. J. M. Juran.Leading source world-wide for research, consulting, and Leading source world-wide for research, consulting, and education in managing for Six Sigma quality to achieve education in managing for Six Sigma quality to achieve superior business results.superior business results.Six Sigma Quality is one of our key businesses today. In Six Sigma Quality is one of our key businesses today. In the present and future, like the past, we have built on our the present and future, like the past, we have built on our competencies - like our competitors. One difference, the competencies - like our competitors. One difference, the Juran Quality Model is the heart of Six Sigma.Juran Quality Model is the heart of Six Sigma.High quality (high sigma values) reduces costs, increases High quality (high sigma values) reduces costs, increases revenues, creates loyal customers and a great culture.revenues, creates loyal customers and a great culture.Not all Six Sigma providers are alike. Juran Institute tries Not all Six Sigma providers are alike. Juran Institute tries to adapt and be flexible in meeting local site requirements, to adapt and be flexible in meeting local site requirements, as well as corporate goals.as well as corporate goals.

WHAT ARE JURAN INSTITUTE’S WHAT ARE JURAN INSTITUTE’S

SERVICES AND PRODUCTS?SERVICES AND PRODUCTS?

Breakthrough Problem Solving

Training E-learning PublicationsConsulting

Services

BooksPapers

BooksPapers

N/AStrategic

Deployment PapersUnder

Development

Provider of Breakthrough Licensing

Design for Six Sigma

DMAIC Six Sigma UnderDevelopment

I- DESIGN FOR SIX SIGMA…I- DESIGN FOR SIX SIGMA…DEFINEDDEFINED

I-DFSS – I-DFSS – – The The Concurrent Development and Introduction Concurrent Development and Introduction of a new or of a new or

radically redesigned product or service and all of the radically redesigned product or service and all of the processes (Design, Procurement, Production, Logistics and processes (Design, Procurement, Production, Logistics and Distribution, Service and Sales) that enable the product or Distribution, Service and Sales) that enable the product or service to achieve Six Sigma business performance.service to achieve Six Sigma business performance.

– A Phased A Phased MethodologyMethodology which includes both the design tools which includes both the design tools and innovative I-TRIZ tools for designing products (goods, and innovative I-TRIZ tools for designing products (goods, information or services) and processes that generate information or services) and processes that generate customer value.customer value.

The phases are The phases are DDefine, efine, MMeasure, easure, AAnalyze, nalyze, DDesign, esign, VVerifyerify

I-DFSS:I-DFSS:New Product/Service Introduction to Achieve Six New Product/Service Introduction to Achieve Six

Sigma Business PerformanceSigma Business Performance

I-DFSS:I-DFSS:New Product/Service Introduction to Achieve Six New Product/Service Introduction to Achieve Six

Sigma Business PerformanceSigma Business Performance

MARKETRESEARCH

MARKETRESEARCH

DESIGNDESIGN

PRODUCTIONPRODUCTION

LOGISTICSLOGISTICS

DISTRIBUTIONDISTRIBUTION

SERVICESERVICE

SALESSALES

DMADV

INNOVATIVE DESIGNS FOR INNOVATIVE DESIGNS FOR SIX SIGMA…DEFINED SIX SIGMA…DEFINED

CUSTOMERSCUSTOMERSCUSTOMERSCUSTOMERS

Customer-driven design of processes with 6 capability.

Predicting design quality up front.

Top down requirements flowdown (CTQ flowdown) matched by capability flowup.

Cross-functional integrated design involvement.

Drives quality measurement and predictability improvement in early design phases.

Utilizes process capabilities to make final design decisions.

Monitors process variances to verify 6 customer requirements are met.

WHAT IS DESIGN FOR SIX WHAT IS DESIGN FOR SIX SIGMA (DFSS)?SIGMA (DFSS)?

THE DMADVTHE DMADVMETHODOLOGY AND TOOLSMETHODOLOGY AND TOOLS

Define Measure Analyze Design Verify

Under-standcustomerneeds andspecifyCTQs

Developdesignconceptsand high-level design

Developdetaileddesign andcontrol/testplan

Testdesign andimplementfull-scaleprocesses

Initiate, scope,and plan theproject

DESIGN FOR SIX SIGMA

DELIVERABLES

TeamCharter

CTQs High-levelDesign

DetailedDesign

Pilot

TOOLS

Mgmt Leadership Customer ResearchFMEA/Errorproofing

Project QFD Process SimulationManagement Benchmarking Design Scorecards

Commercial ElectronicsCommercial Electronics

South Korea based company-wide implementation of Six Sigma, including South Korea based company-wide implementation of Six Sigma, including

South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United

Kingdom and United States.Kingdom and United States.

SOME OF OUR CLIENTS...SOME OF OUR CLIENTS...

Satellite ManufacturerSatellite Manufacturer

Implemented Design for Six SigmaImplemented Design for Six Sigma

SOME OF OUR CLIENTS...SOME OF OUR CLIENTS...

GMGM

FordFord

ToyotaToyota

ChryslerChrysler

EatonEaton

Dana CorporationDana Corporation

Rockwell Int’l AutomotiveRockwell Int’l Automotive

TRW AutomotiveTRW Automotive

ITT AutomotiveITT Automotive

JaguarJaguar

Cost reduction, warrantees, recalls, new design, patent circumvention, failure analysis, failure prediction, training

Break squealBreak squeal

Brake roughnessBrake roughness

Noise and vibrationNoise and vibration

TransmissionTransmission

Air bagAir bag

Electrostatic paintElectrostatic paint

Tail lightTail light

Seat coverSeat cover

Wind tunnelWind tunnel

Plastic fuel tankPlastic fuel tank

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:AUTOMOTIVE INDUSTRYAUTOMOTIVE INDUSTRY

DowDow

AmocoAmoco

DupontDupont

ConocoConoco

SolutiaSolutia

Rohm & HaasRohm & Haas

Cost reduction, breakthrough/discovery, manufacturing processes, safety, quality, reliability, failure analysis

PlasticsPlastics

Chemical processingChemical processing

CatalystsCatalysts

ReactorReactor

Aromatic oxidationAromatic oxidation

Distillation/separationDistillation/separation

New material New material development/designdevelopment/design

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:CHEMICAL INDUSTRYCHEMICAL INDUSTRY

ExxonExxon

MobilMobil

AmocoAmoco

ShellShell

Cost reduction, reliability, failure analysis, new design, training

ExplorationExploration

Method of discoveryMethod of discovery

RefineriesRefineries

Post processingPost processing– GasGas– Fuel oilFuel oil

Enhanced oil recoveryEnhanced oil recovery

Dual grading drillingDual grading drilling

Expandable casingExpandable casing

Hydro carbon processingHydro carbon processing– on shoreon shore– off shoreoff shore

TransportationTransportation

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:OIL INDUSTRYOIL INDUSTRY

Johnson & JohnsonJohnson & Johnson

CardiovascularCardiovascular

RocheRoche

Bristol MyersBristol Myers

Zeneca (UK)Zeneca (UK)

New design, patent circumvention, cost reduction, failure prediction, training

Medical instrumentationMedical instrumentation

Sanitary productsSanitary products

Blister packaging of pillsBlister packaging of pills

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:MEDICAL INDUSTRYMEDICAL INDUSTRY

HoneywellHoneywell

MotorolaMotorola

Philips ElectronicsPhilips Electronics

HitachiHitachi

ITTITT

Arteche (Spain)Arteche (Spain)

VisteonVisteon

Northern Telecon (Canada)Northern Telecon (Canada)

SolarexSolarex

HelixHelix

ToshibaToshiba

SonySony

LG ElectronicsLG Electronics

Cost reduction, new technologies, reliability, manufacturing processes, training

Cell phonesCell phones

MicrochipsMicrochips

PC boardsPC boards

RadioRadio

HeadsetHeadset

High voltage transformersHigh voltage transformers

Power suppliesPower supplies

Navigation systemsNavigation systems

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:ELECTRONICS/ELECTRICAL INDUSTRYELECTRONICS/ELECTRICAL INDUSTRY

BoeingBoeing

Pratt & WhitneyPratt & Whitney

Techspace Aero (Belgium)Techspace Aero (Belgium)

HoneywellHoneywell

Allied SignalAllied Signal

Rockwell InternationalRockwell International

Rolls RoyceRolls Royce

McDonnel Douglas AerospaceMcDonnel Douglas Aerospace

NASANASA

Hughes AircraftHughes Aircraft

TRWTRW

BF GoodrichBF Goodrich

LittonLitton

Cost reduction, safety, reliability, quality, new design, failure analysis and prediction, training

C-17C-17

F-22F-22

EnginesEngines

ValvesValves

Containment ringContainment ring

IDEATION’S SUCCESSES-TO-DATE:IDEATION’S SUCCESSES-TO-DATE:AVIATION INDUSTRYAVIATION INDUSTRY

I-DFSS DESIGN PROJECTI-DFSS DESIGN PROJECTCASE 1CASE 1 CASE 2CASE 2 CASE 3CASE 3

Base Line Performance OK

CurrentProduct

CurrentProduct

DPMOCOPQ

DesignDesign

CurrentProcesses

ManufacturingManufacturing

DistributionDistribution

ServiceService

MarketingMarketing

REDESIGN

Cp, CpkCOPQ

DPMOCOPQ

CurrentProduct

CurrentProduct

NewProcesses

NEW PROCESS DESIGN

Product Base Line Performance OK(May be of little value)

NewProduct

NewProduct

NewProcesses

NEW PRODUCT ANDPROCESS DESIGN

No Base Line Performance

CTQ’sCTQ’s

High-level Design

High-level Design

CTQ GAP“Base Line

Performance”

CTQ GAP“Base Line

Performance”

DesignScorecard

DesignScorecard

But:

No Current Product or Process

DesignDesign

SCIENTIFICALLY BASED APPLICATIONS: SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATIONSYSTEMATIC, STRUCTURED INNOVATION

IPS

DE

AFD

InventiveInventiveProblemProblemSolvingSolving

AnticipatoryAnticipatoryFailureFailure

DeterminationDetermination

Directed EvolutionDirected Evolution

FailureAnalysis

FailurePrediction

Strategically Evolving Future Generations of Technologies & Systems

Surgical Removal of Tough Technological Problems

Invention of Failure Modes Elimination of Contradictions

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

Pre-DEFINE PhasePre-DEFINE Phase

– INTRODUCTION TO SIX SIGMAINTRODUCTION TO SIX SIGMA– HOW TO THINK ABOUT DFSS/NEW PRODUCT HOW TO THINK ABOUT DFSS/NEW PRODUCT

INTRODUCTION (NPI)INTRODUCTION (NPI)– I-TRIZ/Directed Evolution (DE)I-TRIZ/Directed Evolution (DE)

Strategic visionStrategic visionLogical chain of product conceptsLogical chain of product conceptsProduct evolution roadmapProduct evolution roadmap

DEFINE PhaseDEFINE Phase

– INTRODUCTION TO DEFINEINTRODUCTION TO DEFINE– ESTABLISH DESIGN PROJECTESTABLISH DESIGN PROJECT– FINANCIAL ANALYSISFINANCIAL ANALYSIS– PROJECT MANAGEMENT AND RISK PROJECT MANAGEMENT AND RISK

ASSESSMENTASSESSMENT– SUMMARY; ISSUES TO CONSIDERSUMMARY; ISSUES TO CONSIDER

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

MEASURE PhaseMEASURE Phase– INTRODUCTION TO MEASUREINTRODUCTION TO MEASURE– ESTABLISH CTQ’s AND CTI’sESTABLISH CTQ’s AND CTI’s– I-TRIZ/Innovation Situation Questionnaire & Problem FormulatorI-TRIZ/Innovation Situation Questionnaire & Problem Formulator

Design problem documentationDesign problem documentationDesign expectationsDesign expectations

– INTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTIONINTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTION– MSA (Variables, Attribute and Data quality)MSA (Variables, Attribute and Data quality)– PROCESS CAPABILITY (Variables and Attribute)PROCESS CAPABILITY (Variables and Attribute)– RISK ASSESSMENTRISK ASSESSMENT– I-TRIZ/Anticipatory Failure Determination (AFD)I-TRIZ/Anticipatory Failure Determination (AFD)

Failure predictionFailure prediction

– DESIGN SCORECARDDESIGN SCORECARD

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

ANALYZE/HIGH-LEVEL DESIGN PhaseANALYZE/HIGH-LEVEL DESIGN Phase– INTRODUCTION TO HIGH-LEVEL DESIGNINTRODUCTION TO HIGH-LEVEL DESIGN– DEVELOP DESIGN ALTERNATIVESDEVELOP DESIGN ALTERNATIVES– I-TRIZ/Innovative Problem Solving (IPS)I-TRIZ/Innovative Problem Solving (IPS)

Description of design options (alternatives)Description of design options (alternatives)Analysis of design alternatives for technological barriers and Analysis of design alternatives for technological barriers and contradictionscontradictions

– DEVELOP HIGH-LEVEL DESIGN (VA/VE)DEVELOP HIGH-LEVEL DESIGN (VA/VE)– MULTI-VARI ANALYSISMULTI-VARI ANALYSIS– CONFIDENCE INTERVALS AND SAMPLINGCONFIDENCE INTERVALS AND SAMPLING– HYPOTHESIS TESTING AND ANOVAHYPOTHESIS TESTING AND ANOVA– EVALUATE HIGH-LEVEL DESIGNEVALUATE HIGH-LEVEL DESIGN– I-TRIZ/Anticipatory Failure Determination (AFD)I-TRIZ/Anticipatory Failure Determination (AFD)

Failure analysis and prediction Failure analysis and prediction

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

DETAIL DESIGN PhaseDETAIL DESIGN Phase

– INTRODUCTION TO DESIGNINTRODUCTION TO DESIGN– RISK ASSESSMENT/FALURE ANALYSISRISK ASSESSMENT/FALURE ANALYSIS– I-TRIZ/Anticipatory Failure Determination I-TRIZ/Anticipatory Failure Determination

(AFD)(AFD)Failure analysisFailure analysis

– TAGUCHI METHODS AND ROBUST DESIGNTAGUCHI METHODS AND ROBUST DESIGN– TOLERANCINGTOLERANCING– DOE with RSMDOE with RSM

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

DETAIL DESIGN Phase (cont’d)DETAIL DESIGN Phase (cont’d)

– RELIABILITY and AVAILABILITYRELIABILITY and AVAILABILITY– NON-PARAMETRIC STATISTICS NON-PARAMETRIC STATISTICS – SIMULATION with Monte Carlo MethodsSIMULATION with Monte Carlo Methods– DESIGN FOR MANUFACTURABILITY/DESIGN DESIGN FOR MANUFACTURABILITY/DESIGN

FOR ASSEMBLYFOR ASSEMBLY– DVT/TESTABILITYDVT/TESTABILITY– DESIGN SCORECARDDESIGN SCORECARD

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

DETAIL DESIGN Phase -- CUSTOM FEATURESDETAIL DESIGN Phase -- CUSTOM FEATURES

– THE TOOLS OF DETAIL DESIGNTHE TOOLS OF DETAIL DESIGN– CONCURRENT ENGINEERINGCONCURRENT ENGINEERING– SOFTWARE ENGINEERING METHODS AND TOOLS SOFTWARE ENGINEERING METHODS AND TOOLS

(CMM, CASE)(CMM, CASE)ENHANCED DESIGN FOR:Commercial/Competitive SuccessManufacturabilityServiceabilityReliabilityAvailabilityInformation ManagementControl

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

VERIFY PhaseVERIFY Phase– INTRODUCTION TO VERIFYINTRODUCTION TO VERIFY– DESIGN FOR CONTROLDESIGN FOR CONTROL– DESIGN FOR MISTAKE- AND FOOLPROOFINGDESIGN FOR MISTAKE- AND FOOLPROOFING– STATISTICAL PROCESS CONTROL (SPC)STATISTICAL PROCESS CONTROL (SPC)– MVTMVT– TRANSITION TO PROCESS OWNERSTRANSITION TO PROCESS OWNERS– I-TRIZ/Directed Evolution (DE)I-TRIZ/Directed Evolution (DE)

Logical sequence of new scenariosLogical sequence of new scenariosStrategic knowledge base and patent portfolioStrategic knowledge base and patent portfolioTargeted competitive intelligenceTargeted competitive intelligenceNew product evolutionary stagesNew product evolutionary stages

– SUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURESUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURE

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

VERIFY Phase -- CUSTOM FEATURES VERIFY Phase -- CUSTOM FEATURES

– PILOT TESTINGPILOT TESTING– FULL-SIZE SCALE-UP AND FULL-SIZE SCALE-UP AND

COMMERCIALIZATIONCOMMERCIALIZATION– DESIGN INFORMATION AND DATA DESIGN INFORMATION AND DATA

MANAGEMENTMANAGEMENT– LEAN MANUFACTURINGLEAN MANUFACTURING

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

D-M A D V

15 - 16 Weeks

Training

Weeks

Project

1 3 1 4 1 4 - 6 1 4 - 6

IDEAL

VDR-3DDR-2APPD-M

DVT MVT

DR-4

19 - 22 Weeks(5-6 Months)Critical Success Factors:

• Project starts with training• Project < 6 months• Project phases match training schedule

DMADV Training/Project Map DMADV Training/Project Map

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

TrainingProject

(D)

Mass Production

Training(B)

(C)

(A) ?

OK

?

No

Start

REAL

DR-2

Start

DR-3

GapStart

Start

Project

Training

Training

Consulting

Product Planning Project

Project

D-M

DMADV Training/Project Map DMADV Training/Project Map

I- DESIGN FOR SIX SIGMAI- DESIGN FOR SIX SIGMA

Executive Briefing

Preparations

Champion Training/Workshop

Go-No go Decision

Master Black Belt ProgramMaster Black Belt Program

Trained Black Belt

CertificationProject

CertifiedBlack Belt

Black Belt TrainingBlack Belt Training

Define/Measure

Analyze

Design

Verify

D/M

A

D

V

Black Belt ProjectBlack Belt Project

Master BlackBelt Project

Certified MBBs

Statistics, Finance

Leadership Skills

2 days

4-8 hrs JURAN

Sr. Instructor

JURAN

Sr. Instructor

JURAN

INSTRUCTOR(first wave)

Total Duration:4-6 months

Total Duration:4-6 months

JURAN

Sr. INSTRUCTOR

Yes

No?

SIX SIGMA DMADV TRAINING FLOWSIX SIGMA DMADV TRAINING FLOW

DMADVDMADV