Transcription
Design For Six Sigma (DFSS)Introduction24 January 2015Peter K. FungChairman of Hong Kong Society for QualityASQ CQE, ASQ CSSBB
Content1.2.3.4.5.Design For Six SigmaApplication of Design For Six SigmaBenefits of Design For Six SigmaPhilosophy, Methodology and ToolsConclusion
What is DFSS? DFSS is a new development from Six Sigma It is methodology to enhance new productand service development process It provides a more systematic way to managethe deliverable, resources and trade-offs It helps you to deliver better products andservices that your customers want and willingto pay for (at Six Sigma Level)
What is Six Sigma? Developed by Motorola in the mid1980s Jack Welch of GE made it astrategic business managementphilosophy, saving billions ofdollars Spreading from manufacturing intoservicing and other sectors
Six Sigma DMAIC Roadmap
Benefits of Six SigmaBenefits: Delighting Customer Solving Problem Reducing Defect Increasing Profit And more
Problems encountered by Six Sigma1. It does not address the customer values deepenough2. DMAIC-based projects could not solve flaweddesign3. Non-valued added processes cannot beremoved
DFSS Foundations1. Customer-oriented design2. Systematic and creative design3. Robust performance and preventionphilosophy
Example: Six Sigma in Pizza Exprezz (1)Problem: 1 out of 3 customers complained thatthe pizza is not hot enoughReason: it could not be delivered in 30 minSolution: shorted the lead time (DMAIC)Defective RatePerformance Capability1 out of 3 pizzas2σ7 out of 100 pizzas3σ6 out of 1,000 pizzas4σ2 out of 10,000 pizzas5σ3.4 out of 1,000,000 pizzas6σ
Motorola Six Sigma Level
Example: Six Sigma in Pizza Exprezz (2)Business is booming and 2 new pizza ovens wereinstalled to meet the demand .Problem:Reason:Solution:customer complain that the pizzais half-bakedtemperature of ovens, location ofpizza inside the oven, content % ratio,time of baking, etc.go back to everything before problemhappen (by DMAIC)
Example: Six Sigma in Pizza Exprezz (3)Three years later, new population moves in thistown, but new pizza houses open.Problem: customers ask for varieties of pizzaand much lower priceSolution: “Design It Right the First Time”(by DMADV)
Management of Six NT
When to use DFSS?1. Replacing, rather than repairing2. Improving an existing process will never meetthe customers requirements3. An opportunity to offer an entirely newproduct or service
Why DFSS is slow to be taken up?1. Number of Design Number of Improvement2. Risk and amount of resources to deign a newproduct is much higher than that to improvean existing product3. Methods and tools are complicated, andknowledge requirement is high4. Success of DFSS demand on mind-set andattitude (leadership and culture)
Design For Six Sigma (DFSS)DFSS is Free
DFSS DMADV Roadmap
RoadmapsSix Sigma vs Design For SSSix Sigma Improvement (DMAIC)D define the problemdefine the processdefine customer requirement not metM measure extent of the problemdata from process, product andcustomersA analyze the data and process to findthe causes of problemIimprove by eliminating causes ofproblembuild safeguardsC control by regular measure, checkingopportunities for future improvementDesign For Six Sigma (DMADV)D define customer needsdefine “ALL” requirements and gainconsensus on design generationM develop measure of successestablish tolerancedetermine how crucial features beevaluatedA create innovative conceptsnarrow list of concept proposalsD detail the design alternatives listselect the best of the besttesting, testing and testingV validate by testing and deploymentestablish the monitoring systemresponse planning
DFSS Toolbox1. Define- Voice Of Customers (VOC)- Quality Function Deployment (QFD)- Kano Analysis2. Measure- Benchmarking- Capability Performance3. Analyze- TRIZ- Process Simulation4. Design- Failure Mode and Effects Analysis (FMEA)- Design Of Experiences (DOE)- Pugh Matrix5. Verify- Statistics Process Control (SPC)- Response Planning- Process Management
Quality Function Deployment (QFD)
Four Phases of QFD in manufacturing43
Two Phases of QFD in Service
Correlation of Operation Items in QFDWhen I make it stronger, itgets heavier. How can Isolve this contradiction?A B C D E F
Summary (1)ResearchDesignDevelopmentProduction
Summary (2)DFSS – DMDOVSix Sigma - DMAIC
Summary (3)Investment Cost SavingConventional Design100%Cost of Poor DesignDFSS Design50%Prevention CostDesignConceptDesignDevelopmentTesting andOptimizingHandoverTime
Summary (4)Design For Six Sigma Business Benefits: Zero Defects Design Faster Launch of Products Lower Design Costs Lower Product Costs Increasing ProfitBig Picture of Design For Six Sigma: Organization and People innovation andcompetency to Market Challenges
Conclusion“DFSS is free. It is not a gift, but it is free.”Crosby Management and ConsultantPhilosophy: Cost of Poor Design
Six Sigma Improvement (DMAIC) Design For Six Sigma (DMADV) D define the problem define the process define customer requirement not met D define customer needs define “ALL” requirements and gain consensus on design generation M measure extent of the problem data from process, product and customers M develop measure of success establish tolerance determine how crucial features be
