DFSS, Innovation and I-TRIZ Tools “Innovative Designs for Six Sigma”

1. DFSS, Innovation and I-TRIZ Tools “Innovative Designs for Six Sigma”

2. BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN ORIGINS Global Leaders in their fields Dr. Joseph M. Juran Father of Breakthrough Improvement Genrich Saulovich AltshullerFather of TRIZ

3. OUR CREDIBILITY AND EXPERIENCE • A 23-year successful Juran track record in achieving bottom-line resultsthrough 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 Institutestaff 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.

4. IDEATION INTERNATIONAL INC. • Ideation established 1992 • Merged with Kishinev School (Leading TRIZ School in Russia) • Headquarters in Southfield, MI • 85% of the world’s leading TRIZ Scientists • Installed customer base of over 2,000 enterprises worldwide • Active in 40 countries and 65 universities plus numerous partnerships, strategic alliances and resellers established worldwide

5. IDEATION’S MISSION 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.

6. WHAT IS IDEATION’S BUSINESS? Provider of I-TRIZ: Education Software Publications Analytical Services Age of Application Inventive Problem Solving Books Papers 54 yrs Failure Analysis 22 yrs Anticipatory Failure Determination Book Papers Failure Prediction 22 yrs Directed Evolution Under Development Papers 12 yrs

7. Our mission is to provide professional consulting services to improve continuously the performance of our clients’ processes, products, people, and profits. JURAN INSTITUTE’S MISSION

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

9. WHAT ARE JURAN INSTITUTE’S SERVICES AND PRODUCTS? Provider of Breakthrough Training E-learning Publications Consulting Services Licensing Breakthrough Problem Solving Books Papers Design for Six Sigma Books Papers Under Development DMAIC Six Sigma N/A Strategic Deployment Under Development Papers

10. I- DESIGN FOR SIX SIGMA…DEFINED • I-DFSS – • The Concurrent Development and Introduction of a new or radically redesigned product or service and all of the processes (Design, Procurement, Production, Logistics and Distribution, Service and Sales) that enable the product or service to achieve Six Sigma business performance. • A Phased Methodology which includes both the design tools and innovative I-TRIZ tools for designing products (goods, information or services) and processes that generate customer value. • The phases are Define, Measure, Analyze, Design, Verify

11. INNOVATIVE DESIGNS FOR SIX SIGMA…DEFINED I-DFSS: New Product/Service Introduction to Achieve Six Sigma Business Performance MARKET RESEARCH DESIGN PRODUCTION LOGISTICS DISTRIBUTION SERVICE DMADV SALES CUSTOMERS

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

13. Define Measure Analyze Design Verify TeamCharter Pilot DetailedDesign CTQs High-levelDesign THE DMADVMETHODOLOGY AND TOOLS DESIGN FOR SIX SIGMA Initiate, scope,and plan theproject Under-standcustomerneeds andspecifyCTQs Developdesignconceptsand high-level design Developdetaileddesign andcontrol/testplan Testdesign andimplementfull-scaleprocesses DELIVERABLES TOOLS Mgmt Leadership  Customer Research  FMEA/Errorproofing Project QFD Process Simulation Management Benchmarking Design Scorecards

14. SOME OF OUR CLIENTS... Commercial Electronics South Korea based company-wide implementation of Six Sigma, including South Korea, Hungary, India, Indonesia, Malaysia, Mexico, Spain, United Kingdom and United States.

15. SOME OF OUR CLIENTS... Satellite Manufacturer Implemented Design for Six Sigma

16. IDEATION’S SUCCESSES-TO-DATE:AUTOMOTIVE INDUSTRY • Dana Corporation • Rockwell Int’l Automotive • TRW Automotive • ITT Automotive • Jaguar • GM • Ford • Toyota • Chrysler • Eaton Cost reduction, warrantees, recalls, new design, patent circumvention, failure analysis, failure prediction, training • Break squeal • Brake roughness • Noise and vibration • Transmission • Air bag • Electrostatic paint • Tail light • Seat cover • Wind tunnel • Plastic fuel tank

17. IDEATION’S SUCCESSES-TO-DATE:CHEMICAL INDUSTRY • Conoco • Solutia • Rohm & Haas • Dow • Amoco • Dupont Cost reduction, breakthrough/discovery, manufacturing processes, safety, quality, reliability, failure analysis • Plastics • Chemical processing • Catalysts • Reactor • Aromatic oxidation • Distillation/separation • New material development/design

18. IDEATION’S SUCCESSES-TO-DATE:OIL INDUSTRY • Amoco • Shell • Exxon • Mobil Cost reduction, reliability, failure analysis, new design, training • Exploration • Method of discovery • Refineries • Post processing • Gas • Fuel oil • Enhanced oil recovery • Dual grading drilling • Expandable casing • Hydro carbon processing • on shore • off shore • Transportation

19. IDEATION’S SUCCESSES-TO-DATE:MEDICAL INDUSTRY • Bristol Myers • Zeneca (UK) • Johnson & Johnson • Cardiovascular • Roche New design, patent circumvention, cost reduction, failure prediction, training • Medical instrumentation • Sanitary products • Blister packaging of pills

20. IDEATION’S SUCCESSES-TO-DATE:ELECTRONICS/ELECTRICAL INDUSTRY • Northern Telecon (Canada) • Solarex • Helix • Toshiba • Sony • LG Electronics • Honeywell • Motorola • Philips Electronics • Hitachi • ITT • Arteche (Spain) • Visteon Cost reduction, new technologies, reliability, manufacturing processes, training • Cell phones • Microchips • PC boards • Radio • Headset • High voltage transformers • Power supplies • Navigation systems

21. IDEATION’S SUCCESSES-TO-DATE:AVIATION INDUSTRY • Rolls Royce • McDonnel Douglas Aerospace • NASA • Hughes Aircraft • TRW • BF Goodrich • Litton • Boeing • Pratt & Whitney • Techspace Aero (Belgium) • Honeywell • Allied Signal • Rockwell International Cost reduction, safety, reliability, quality, new design, failure analysis and prediction, training • C-17 • F-22 • Engines • Valves • Containment ring

22. New Processes New Processes I-DFSS DESIGN PROJECT CASE 1 CASE 2 CASE 3 No Current Product or Process  DPMO COPQ  DPMO COPQ CurrentProduct CurrentProduct NewProduct But: CTQ’s Current Processes High-level Design Design Design CTQ GAP“Base LinePerformance” Manufacturing  Cp, Cpk COPQ Distribution DesignScorecard Service Marketing REDESIGN NEW PROCESS DESIGN NEW PRODUCT AND PROCESS DESIGN Base Line Performance OK Product Base Line Performance OK(May be of little value) No Base Line Performance

23. SCIENTIFICALLY BASED APPLICATIONS: SYSTEMATIC, STRUCTURED INNOVATION Strategically Evolving Future Generations of Technologies & Systems Directed Evolution DE Inventive Problem Solving Anticipatory Failure Determination AFD IPS Surgical Removal of Tough Technological Problems Failure Analysis Failure Prediction Elimination of Contradictions Invention of Failure Modes

24. I- DESIGN FOR SIX SIGMA • Pre-DEFINE Phase • INTRODUCTION TO SIX SIGMA • HOW TO THINK ABOUT DFSS/NEW PRODUCT INTRODUCTION (NPI) • I-TRIZ/Directed Evolution (DE) • Strategic vision • Logical chain of product concepts • Product evolution roadmap

25. I- DESIGN FOR SIX SIGMA • DEFINE Phase • INTRODUCTION TO DEFINE • ESTABLISH DESIGN PROJECT • FINANCIAL ANALYSIS • PROJECT MANAGEMENT AND RISK ASSESSMENT • SUMMARY; ISSUES TO CONSIDER

26. I- DESIGN FOR SIX SIGMA • MEASURE Phase • INTRODUCTION TO MEASURE • ESTABLISH CTQ’s AND CTI’s • I-TRIZ/Innovation Situation Questionnaire & Problem Formulator • Design problem documentation • Design expectations • INTRODUCTION TO PROBABILITY, STATISTICS AND PREDICTION • MSA (Variables, Attribute and Data quality) • PROCESS CAPABILITY (Variables and Attribute) • RISK ASSESSMENT • I-TRIZ/Anticipatory Failure Determination (AFD) • Failure prediction • DESIGN SCORECARD

27. I- DESIGN FOR SIX SIGMA • ANALYZE/HIGH-LEVEL DESIGN Phase • INTRODUCTION TO HIGH-LEVEL DESIGN • DEVELOP DESIGN ALTERNATIVES • I-TRIZ/Innovative Problem Solving (IPS) • Description of design options (alternatives) • Analysis of design alternatives for technological barriers and contradictions • DEVELOP HIGH-LEVEL DESIGN (VA/VE) • MULTI-VARI ANALYSIS • CONFIDENCE INTERVALS AND SAMPLING • HYPOTHESIS TESTING AND ANOVA • EVALUATE HIGH-LEVEL DESIGN • I-TRIZ/Anticipatory Failure Determination (AFD) • Failure analysis and prediction

28. I- DESIGN FOR SIX SIGMA • DETAIL DESIGN Phase • INTRODUCTION TO DESIGN • RISK ASSESSMENT/FALURE ANALYSIS • I-TRIZ/Anticipatory Failure Determination (AFD) • Failure analysis • TAGUCHI METHODS AND ROBUST DESIGN • TOLERANCING • DOE with RSM

29. I- DESIGN FOR SIX SIGMA • DETAIL DESIGN Phase (cont’d) • RELIABILITY and AVAILABILITY • NON-PARAMETRIC STATISTICS • SIMULATION with Monte Carlo Methods • DESIGN FOR MANUFACTURABILITY/DESIGN FOR ASSEMBLY • DVT/TESTABILITY • DESIGN SCORECARD

30. I- DESIGN FOR SIX SIGMA • DETAIL DESIGN Phase -- CUSTOM FEATURES • THE TOOLS OF DETAIL DESIGN • CONCURRENT ENGINEERING • SOFTWARE ENGINEERING METHODS AND TOOLS (CMM, CASE) ENHANCED DESIGN FOR: • Commercial/Competitive Success • Manufacturability • Serviceability • Reliability • Availability • Information Management • Control

31. I- DESIGN FOR SIX SIGMA • VERIFY Phase • INTRODUCTION TO VERIFY • DESIGN FOR CONTROL • DESIGN FOR MISTAKE- AND FOOLPROOFING • STATISTICAL PROCESS CONTROL (SPC) • MVT • TRANSITION TO PROCESS OWNERS • I-TRIZ/Directed Evolution (DE) • Logical sequence of new scenarios • Strategic knowledge base and patent portfolio • Targeted competitive intelligence • New product evolutionary stages • SUMMARY; ISSUES TO CONSIDER; PROJECT CLOSURE

32. I- DESIGN FOR SIX SIGMA • VERIFY Phase -- CUSTOM FEATURES • PILOT TESTING • FULL-SIZE SCALE-UP AND COMMERCIALIZATION • DESIGN INFORMATION AND DATA MANAGEMENT • LEAN MANUFACTURING

33. I- DESIGN FOR SIX SIGMA  DMADV Training/Project Map IDEAL 15 - 16 Weeks Training Weeks Project D-M A D V 1 3 1 4 1 4 - 6 1 4 - 6 D-M PP A DR-2 D DR-3 V DR-4 DVT MVT 19 - 22 Weeks (5-6 Months) • Critical Success Factors: • Project starts with training • Project < 6 months • Project phases match training schedule

34. Product Planning Project Project I- DESIGN FOR SIX SIGMA  DMADV Training/Project Map REAL (A) ? Training Project Mass Production Start DR-2 OK (B) D-M Training Start Consulting (C) ? Training Start DR-3 No (D) Training Project Gap Start

35. Define/Measure D/M Analyze A Design D Verify V Certification Project Statistics, Finance Leadership Skills SIX SIGMA DMADV TRAINING FLOW JURANSr. Instructor Executive Briefing 4-8 hrs Preparations JURANSr. Instructor Champion Training/Workshop 2 days DMADV Go-No go Decision Black Belt Training Black Belt Project JURANINSTRUCTOR(first wave) Total Duration: 4-6 months Trained Black Belt CertifiedBlack Belt No ? Yes Master Black Belt Program JURANSr. INSTRUCTOR Total Duration: 4-6 months Master BlackBelt Project Certified MBBs