Design for Six Sigma (DFSS) is a business process focused on improving profitability. Properly applied, it generates the right product at the right time at the right cost. Through its use of product and team scorecards, it is a powerful program management technique. DFSS is an enhancement to your new product development process, not a replacement for it. A documented, well-understood and useful new product development process is fundamental to a successful DFSS process. You will be provided with the framework, tools and processes for a proven, superior approach to developing a new product and associated processes from inception to production sign off: DMADV (Define, Measure, Analyze, Design, Validate). The course has two complementary goals: (1) Provide all participants with an overview, motivation,and structure for DFSS, and (2) Provide an opportunity for participants who are currently developing a new product or process to apply the DFSS road map to their projects.
What You Will Learn:
- Apply DFSS to a new product or process development
- Build a house of quality
- Differentiate between DMADV and DMAIC
- Explain the structure of DFSS
The generally accepted body of knowledge for Design for Six Sigma (DFSS) lists the following subheadings:
- Quality function deployment (QFD)
- Robust design and processes (includes functional requirements)
- Failure modes and effects analysis (FMEA)
- Design for X (DFX)
- Special design tools
General Electric has defined the principles of DFSS as the following:
- Disciplined CTQ flowdown
- Controlled design parameters
- Product performance modeled and simulated
- Designed for robust performance and producibility
- Functionally integrated product development
- Quality “designed in”
The IIE course expands on the generally accepted body of knowledge and the General Electric definitions to provide participants with specific details and applications of the DFSS framework to enable them to:
- Understand real customer needs through voice of the customer (VOC) analysis.
- Use quality function deployment (QFD) to translate customer needs into critical technical characteristics of the product and ultimately into critical to quality (CTQ) characteristics of the product and process.
- Focus on designing for the lifecycle to minimize lifecycle costs with DFMA, value analysis and target costing/DTC and to enhance reliability with design for reliability and DFT.
- Mistake-proof the product and process.
- Perform failure modes and effects analysis (FMEA) or anticipatory failure determination (AFD) to identify potential failures and take corrective action to mitigate or prevent those failures. FMEA and AFD apply to both the design of the product and the design of the process.
- Develop capable manufacturing processes and select processes that are capable of meeting the design requirements, especially with CTQ parameters.
- Use Design of Experiments (DOE) or Taguchi methods to optimize parameter values and reduce variation; in other words, develop a robust design.
- Verify and validate the product design will meet customer needs with peer reviews, checklists, design reviews, simulation and analysis, qualification testing, production validation testing, focus groups and market testing.
- Measure results with DFSS scorecard; estimate sigma - do results meet quality target?
IIE reserves the right to cancel a class up to 15 business days prior to the scheduled start date