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Phong Q. Vo Dec 2, 2011

Design For Six Sigma & Structured Innovation. Phong Q. Vo Dec 2, 2011. Credentials. B.A.Sci. in Mechanical Engineering, UW, 1989 M. Eng.in Mechanical Engineering, UWO, 2003 M.B.A., WLU, 2006 Certified DFSS BB since 2007 A member of PEO since 1993

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Phong Q. Vo Dec 2, 2011

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  1. Design For Six Sigma & Structured Innovation Phong Q. Vo Dec 2, 2011

  2. Credentials • B.A.Sci. in Mechanical Engineering, UW, 1989 • M. Eng.in Mechanical Engineering, UWO, 2003 • M.B.A., WLU, 2006 • Certified DFSS BB since 2007 • A member of PEO since 1993 • GM/GDLS employee since 1990, held various positions in engineering department (Design, Computer Modeling & Simulation, Engineering Quality, Systems Engineering) • A good friend of Dr. P. Kurowski

  3. Topics of Discussion • Definition of Quality • What is 6 sigma? • 6 sigma benchmark • Lean six sigma (LSS), Design For Six Sigma (DFSS), Differences • Phases in a DFSS project • Structured Innovation & TRIZ • Questions

  4. Definition of Quality • “A characteristic or attribute of something; property; a feature” – The Houghton Mifflin Canadian Dictionary • “Characteristic of a product or service that satisfies the customer's wants and needs in exchange for monetary considerations” - Web definition • “High quality product or service can only be achieved by well/systematically designed process, disciplined execution, and the right attitude of the people involved” –P.Q.V.

  5. What is Six Sigma ? • A disciplined, statistically driven methodology for eliminating or reducing defects (or waste) in any process. • Originally developed by engineers at Motorola in the 1980’s to improve the company’s quality monitoring process. • To day, the six sigma principles are used worldwide as a management tool to improve business outcomes.

  6. An illustration Process to meet control limits Sdfsdfsd Sdffsdf Czxczxc Czxczxc czx Sdfsdfsd sdffsdf Control Limits established to meet customer expectations

  7. 6 Sigma Process Benchmark

  8. What is Lean Six Sigma (LSS)? • The application of lean six sigma philosophy to produce better products, at faster rates, and at lower costs. • Lean means eliminating non-value added steps in a process. • Six Sigma means reducing variation of a lean process. In other words, the process produces no more than 3.4 defects per million. • Synonymous with DMAIC (Define, Measure, Analyze, Improve, Control)

  9. What is Design For Six Sigma (DFFS)? • A proactive, predictive, and systematic design approach to develop six sigma quality level products or services. • Synonymous with DCOV (Define, Characterize, Optimize, Validate)

  10. Main Differences between DFSS and LSS ?

  11. Phases in a DFSS project Define Characterize Optimize Validate

  12. Define Define Phase • Voice of Customers (VOC) • House of Quality #1 • CTC (Critical to Customers) • Balance Scorecard (Parts, Process, Performance, Software)

  13. Characterize Phase Characterize • Systems Engineering & Requirements Flow-down • House of Quality #2 • Creation of Transfer Function (DOE, EVA) • Design Concept Development • Design Risk Assessment • Design Concept Selection

  14. Optimize Optimize • Design for Robust Performance • Tolerance Allocation • Design for X (Manufacturability, Reliability, Maintainability, Assembly, etc.) • Product Capability Prediction

  15. Validate Validate • Prototype construction • Predicted vs. Actual comparison • Sensitivity Analysis

  16. Structured Innovation - TRIZ • TRIZ stands for “Teoriya Resheniya Izobreatatelskikh Zadatch” (A Russion acronym). It means “Theory of Inventive Problem Solving” • Genrich Altshuller, the father of TRIZ • Born in Oct. 1926, in Tashkent, USSR • Died on Sept. 24th, 1998 in Petrozavodsk, Russia. • An engineer, inventor, scientist, journalist, and writer. • The story of G. Altshuller at Gulag concentration camp

  17. More on Altshuller & TRIZ

  18. More on Altshuller & TRIZ • Altshuller screened over 200,000 patents and looked for patterns in problem solving techniques • Altshuller concluded that • There are a finite number of potential problems and solutions in the universe • Innovation is a solution resolving major design conflicts (physical & technical contradictions) • All problems can be framed within 39 parameters • They can be solved using 40 principles

  19. Traditional Problem Solving Process The Wall Ideal Solution Problem A Traditional Problem Solving Process

  20. TRIZ Process Ideal Solution Problem A TRIZ Process starts here

  21. TRIZ Process Specific Problem Specific Solutions Generic Problem Generic Solution

  22. Questions

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