Design for Lean Six Sigma : A Holistic Approach to Design and Innovation

by Jugulum, Rajesh; Samuel, Philip

• ISBN13: 9780470007518
• ISBN10: 0470007516
• Format: Hardcover
• Copyright: 2008-04-11
• Publisher: Wiley

Summary

Design for Lean Six Sigmais the only book that employs a "road-map" approach to DFSS, which allows corporate management to understand where they are in the process and to integrate DFSS methodology more fully into their overall business strategy. This is a similar approach to that used by Forrest Breyfogle in his successful book: "Implementing Six Sigma, 2E". This approach will allow corporate management to understand where they are in the process and to integrate DFSS methodology more fully into the overall business strategy. Another important aspect of this book is its coverage of DFSS implementation in a broad range of industries including service and manufacturing, plus the use of actual cases throughout.

Author Biography

Dr. Rajesh Jugulum is a Vice President of the Global Wealth and Investment Division of Bank of America. He is also affiliated with the robust design group at the Massachusetts Institute of Technology. He has published several articles in leading technical journals andmagazines and coauthored two books related to Mahalanobis-Taguchi Strategy and Computer-Based Robust Engineering with Dr. Genichi Taguchi, in addition to holding a U.S. patent. He is the recipient of the 2002 American Society for Quality's Feigenbaum Medal and the 2006 International Technology Institute's Rockwell Medal. He was inducted into the World Level of the Hall of Fame for Engineering, Science, and Technology in 2006 and in the same year, was listed in Who's Who in the World by Marquis Who's Who publication board. He was featured as the "Face of Quality" in September 2001 issue of Quality Progress.

Dr. Philip Samuel is the Chief Innovation Officer for the Breakthrough Management Group, a management consulting firm specializing in performance excellence and innovation. He has been active in the management of innovation, design, and operations areas for over twenty years. He has consulted with numerous industrial and governmental organizations including Alberta Research Council, Ameriprise Financial, AXA, Baxter BioScience, BMW, ConocoPhillips, Environment Canada, Hess Corporation, Hitachi Global Storage Technologies, Johnson Controls, Kaiser Permanente, Merrill Lynch, McKesson, National Research Council of Canada, Rhodia, Schlumberger, Saint-Gobain, and Textron. He holds a PhD from the University of Calgary and an MBA from Arizona State University.

Table of Contents

Preface	p. xv
Acknowledgments	p. xix
Introduction	p. 1
The Goal	p. 1
Design for Six Sigma - State of the Art	p. 2
Approach	p. 3
Guide to This Book	p. 7
Driving Growth through Innovation	p. 11
Delivering on the Promise	p. 11
Creating a Better Promise	p. 12
Ambidextrous Organization	p. 14
Platforms for Growth	p. 17
Innovation and Design	p. 18
Managing the Paradox of Preservation and Evolution	p. 20
Types of Paradoxes	p. 21
Conclusions	p. 28
Process for Systematic Innovation	p. 29
Balanced Innovation Portfolio	p. 30
Effective Teams for Collaboration	p. 32
Process for Executing Innovation Projects	p. 35
Proven Techniques and Tools	p. 38
Climate for Innovation	p. 39
The Governance System	p. 40
Lean Six Sigma Essentials	p. 41
Origins of Six Sigma	p. 42
Six Sigma Approach	p. 43
Origins of Lean	p. 47
Lean Six Sigma: Faster, Better, and Cheaper	p. 55
Deploying Design for Lean Six Sigma	p. 59
Deploying DFLSS	p. 59
Design for Lean Six Sigma Enterprise	p. 66
Executive Sponsors	p. 67
Deployment Champions	p. 68
Design Project Champions	p. 68
Design Black Belts	p. 68
Core Team	p. 68
Extended Team	p. 69
Building Support Infrastructure	p. 69
Capturing the Voice of the Customer	p. 73
Defining Elements of Customer-Producer Relationship	p. 75
Customer Expectations	p. 78
Methods of Collecting Customer Expectations	p. 83
Research Ethics	p. 89
Design Axioms and Their Usefulness in DFLSS	p. 91
Design Axioms	p. 92
Domain Thinking	p. 93
Designing of MTS Software System	p. 96
Designing a System that Will Market Sporting Goods	p. 101
Designing a Fan Belt/Pulley System	p. 104
Use of Design Principles in an Academic Department	p. 106
Mechanical Engineering Department at MIT	p. 106
FR-DP Identification	p. 108
Actions Taken	p. 109
Designing a University System that Will Teach Students Only through the Internet	p. 112
Implementing Lean Design	p. 115
Key Principles of Lean Design	p. 115
Strategies for Maximizing Value and Minimizing Costs and Harm	p. 118
Modular Designs	p. 118
Value Engineering	p. 122
The 3P (Production, Preparation, Process) Approach	p. 123
Theory of Inventive Problem Solving (TRIZ)	p. 127
Introduction to TRIZ	p. 127
TRIZ Journey	p. 129
TRIZ Road Map	p. 129
Ideality Equation	p. 131
Itself Method	p. 132
TRIZ Analysis Tools	p. 132
TRIZ Database Tools	p. 139
Case Examples of TRIZ	p. 147
Improving the Process of Fluorination	p. 147
Coordinate Measuring Machine (CMM) Support Problem	p. 152
Robustness through Inventions	p. 157
What Is a Robustness Invention?	p. 159
Research Methodology	p. 160
Results of the Patent Search	p. 161
Robust Invention Classification Scheme	p. 161
Signal-based-Robust Invention	p. 163
Response-based Robust Invention	p. 165
Noise-factor-based Robust Invention	p. 167
Control-factor-based Robust Invention	p. 169
Design for Robustness	p. 171
Engineered Quality	p. 171
Evaluation of the Function Using Energy Transformation	p. 173
Studying the Interactions between Control and Noise Factors	p. 174
Use of Orthogonal Arrays (OAs) and Signal-to-Noise Ratios to Improve Robustness	p. 174
Two-step Optimization	p. 174
Tolerance Design Using Quality Loss Function	p. 174
Additional Topics in Designing for Robustness	p. 175
Parameter Diagram (P-diagram)	p. 175
Design of Experiments	p. 176
Signal-to-Noise (S/N) Ratios	p. 178
Role of Simulations in Design for Robustness	p. 179
Example - Circuit Stability Design	p. 180
Control Factors and Noise Factors	p. 181
Parameter Design	p. 182
PCB Drilled-hole Quality Improvement	p. 184
Introduction	p. 185
Drilled-hole Quality Characteristics	p. 186
Background	p. 186
Hole-quality Standard	p. 187
Experiment Description	p. 190
Selection of Levels for These Factors	p. 191
Designing the Experiment	p. 192
Predictions and Confirmation Run	p. 195
Benefits	p. 196
Design of a Valveless Micropump Using Taguchi Methods	p. 197
Introduction	p. 197
Working Principle and Finite Element Modeling	p. 199
Design for Robustness	p. 200
Conclusions	p. 208
Robust System Testing	p. 209
Introduction	p. 209
A Typical System Used in Testing	p. 210
Role of the Orthogonal Arrays	p. 211
Method of Software Testing	p. 212
Study of Two-factor Combinations	p. 213
Construction of Combination Tables	p. 213
MTS Software Testing (Case Study 1)	p. 215
Case Study 2	p. 219
Analysis of Results	p. 221
Debugging the Software	p. 221
Conclusions	p. 223
Development of Multivariate Measurement System Using the Mahalanobis-Taguchi Strategy	p. 225
What Is Mahalanobis-Taguchi Strategy?	p. 226
Stages in MTS	p. 229
Signal-to-Noise Ratio - A Measure of Prediction Accuracy	p. 231
Types of S/N Ratios in MTS	p. 232
Medical Case Study	p. 234
Stage 1: Development of Measurement Scale Using Mahalanobis Space	p. 234
Stage 2: Validation of the Measurement Scale	p. 235
Stage 3: Identification of Useful Variables (Development Stage)	p. 236
Case Example 2: Auto Marketing Case Study	p. 240
Introduction	p. 240
Construction of Mahalanobis Space	p. 241
Validation of the Measurement Scale	p. 241
Identification of Useful Variables	p. 242
Case Study 3: Improving Client Experience	p. 245
Methodology	p. 245
Improvements Made Based on Recommendations from MTS Analysis	p. 246
Improvement of the Utility Rate of Nitrogen while Brewing Soy Sauce	p. 247
Introduction	p. 247
Process of Producing Soy Sauce or Tamari	p. 248
Selection of Factors for MTS Application	p. 248
MTS for Aging	p. 249
MTS for Koji-molding	p. 249
Application of MTS for Measuring Oil in Water Emulsion	p. 250
Introduction	p. 250
Application of MTS	p. 251
Prediction of Fasting Plasma Glucose (FPG) from Repetitive Annual Health Check-up Data	p. 252
Introduction	p. 252
Diabetes Mellitus	p. 253
Application of MTS	p. 253
References	p. 255
Appendixes	p. 263
TRIZ Contradiction Matrix	p. 265
40 TRIZ Inventive Principles	p. 267
Some Useful Orthogonal Arrays	p. 269
Equations for Signal-to-noise (S/N) Ratios	p. 277
Related Topics of Matrix Theory	p. 281
Index	p. 287
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