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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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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 • 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
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
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.
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.
An illustration Process to meet control limits Sdfsdfsd Sdffsdf Czxczxc Czxczxc czx Sdfsdfsd sdffsdf Control Limits established to meet customer expectations
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)
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)
Phases in a DFSS project Define Characterize Optimize Validate
Define Define Phase • Voice of Customers (VOC) • House of Quality #1 • CTC (Critical to Customers) • Balance Scorecard (Parts, Process, Performance, Software)
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
Optimize Optimize • Design for Robust Performance • Tolerance Allocation • Design for X (Manufacturability, Reliability, Maintainability, Assembly, etc.) • Product Capability Prediction
Validate Validate • Prototype construction • Predicted vs. Actual comparison • Sensitivity Analysis
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
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
Traditional Problem Solving Process The Wall Ideal Solution Problem A Traditional Problem Solving Process
TRIZ Process Ideal Solution Problem A TRIZ Process starts here
TRIZ Process Specific Problem Specific Solutions Generic Problem Generic Solution