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9780130092236

Design for Six Sigma in Technology and Product Development

by ; ;
  • ISBN13:

    9780130092236

  • ISBN10:

    0130092231

  • Edition: 1st
  • Format: Hardcover
  • Copyright: 2002-10-25
  • Publisher: Prentice Hall
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List Price: $130.00

Summary

Technology companies can only achieve the full benefits of Six Sigma if they implement it proactively, starting with the earliest stages of technology development and product design, link it to a well-structured product development process, and rigorously manage it.Design for Six Sigma in Technology and Product Developmentshows how. Authors Clyde Creveling, Jeff Slutsky, and David Antis Jr. present step-by-step techniques, flow diagrams, scorecards, and checklists, plus the first complete introduction to Critical Parameter Management (CPM), the breakthrough approach to managing complex product development.

Author Biography

C. M. Creveling, DFSS Product Manager for Assembled Products and Project Manager/Master Consultant for a major Six Sigma Consulting firm J. L. Slutsky has 20 years' experience designing and developing complex medical and image processing products D. Antis, Jr., CEO of a new global consulting firm and former Vice President of Operations for SBTI

Table of Contents

Foreword.
Preface.
Acknowledgments.

I. INTRODUCTION TO ORGANIZATIONAL LEADERSHIP, FINANCIAL PERFORMANCE, AND VALUE MANAGEMENT USING DESIGN FOR SIX SIGMA.

1. The Role of Executive and Management Leadership in Design for Six Sigma.
Leadership Focus on Product Development as Key Business Process. The Strategic View of Top-Line Growth. Enabling Your Product Development Process to Have the Ability to Produce the Right Data, Deliverables, and Measures of Risk within the Context of Your Phase/Gate Structure. Executive Commitment to Driving Culture Change. Summary. References.

2. Measuring Financial Results from DFSS Programs and Projects.
A Case Study. Deploying the Voice of the Customer. DFSS Project Execution Efficiency. Production Waste Minimization. Pricing and Business Risk.

3. Managing Value with Design for Six Sigma.
Extracting Value. Value as a Formula. Measuring Value in the Marketplace. Identifying the Purposes of Design. Design Based on the Voice of the Customer. Putting Concept Engineering to Work. References.

II. INTRODUCTION TO THE MAJOR PROCESSES USED IN DESIGN FOR SIX SIGMA IN TECHNOLOGY AND PRODUCT DEVELOPMENT.


4. Management of Product Development Cycle-Time.
The Product Development Process Capability Index. Product Development Process. Project Management. The Power of PERT Charts. References.

5. Technology Development Using Design For Six Sigma.
The I2DOV Roadmap: Applying a Phase/Gate Approach to Technology Development. I2DOV and Critical Parameter Management during the Phases and Gates of Technology Development. I2DOV Phase 1: Invention and Innovation. I2DOV Phase 2: Develop Technology Concept Definition, Stabilization, and Functional Modeling. I2DOV Phase 3: Optimization of the Robustness of the Subsystem Technologies. I2DOV Phase 4: Certification of the Platform or Subsystem Technologies. References.

6. Product Design Using Design for Six Sigma.
An Introduction to Phases and Gates. Preparing for Product Commercialization. Defining a Generic Product Commercialization Process Using CDOV Roadmap. The CDOV Process and Critical Parameter Management during the Phases and Gates of Product Commercialization. CDOV Phase 2: Subsystem Concept and Design Development. CDOV Phase 3A: Optimizing Subsystems. CDOV Phase 3B: System Integration. CDOV Phase 4A: Verification of Product Design Functionality. CDOV Phase 4B: Verification of Production. References.

7. System Architecting, Engineering, and Integration Using Design for Six Sigma.
Phase 1: System Concept Development. Phase 2: Subsystem, Subassembly, Component, and Manufacturing Concept Design. Phase 3A: Subsystem Robustness Optimization. Phase 3B: System Integration. Phase 4A: Final Product Design Certification. Phase 4B: Production Verification. References.

III. INTRODUCTION TO THE USE OF CRITICAL PARAMETER MANAGEMENT IN DESIGN FOR SIX SIGMA IN TECHNOLOGY AND PRODUCT DEVELOPMENT.


8. Introduction to Critical Parameter Management.
Winning Strategies. Focus on System Performance. Data-Driven Process. The Best of Best Practices. Reference.

9. The Architecture of the Critical Parameter Management Process.
Who Constructs the CPM Process? Timing Structure of the CPM Process: Where and When Does CPM Begin? What Are the Uses of CPM? Reference.

10. The Process of Critical Parameter Management in Product Development.
Definitions of Terms for Critical Parameter Management. Critical Parameter Management in Technology Development and Product Design: Phase 1. Phase 2 in Technology Development or Product Design. Phases 3 and 4: Stress Testing and Integration. Capability Summaries and the Capability Growth Index.

11. The Tools and Best Practices of Critical Parameter Management.
The Rewards of Deploying Proven Tools and Best Practices. Critical Parameter Management Best Practices for Technology Development. Critical Parameter Management Best Practices for Product Commercialization.

12. Metrics for Engineering and Project Management Within CPM.
Key CPM Metrics. Statistical Metrics of CPM. The Capability Growth Index and the Phases and Gates of Technology Development and Product Commercialization.

13. Data Acquisition and Database Architectures in CPM.
Instrumentation, Data Acquisition, and Analysis in CPM. Databases: Architectures and Use in CPM. References.

IV. TOOLS AND BEST PRACTICES FOR INVENTION, INNOVATION, AND CONCEPT DEVELOPMENT.


14. Gathering and Processing the Voice of the Customer: Customer Interviewing and the KJ Method.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? Gathering and Processing the Voice of the Customer Process Flow Diagram. Verbal Descriptions of the Application of Each Block Diagram. VOC Gathering and Processing Checklist and Scorecard. References.

15. Quality Function Deployment: The Houses of Quality.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? QFD Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. QFD Checklist and Scorecards. References.

16. Concept Generation and Design for x Methods.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? Concept Generation and DFx Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Concept Generation and DFx Checklist and Scorecards. References.

17. The Pugh Concept Evaluation and Selection Process.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? The Pugh Concept Selection Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Pugh Concept Selection Process Checklist and Scorecard. References.

18. Modeling: Ideal/Transfer Functions, Robustness Additive Models, and the Variance Model.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? Modeling Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Modeling Checklist and Scorecard. References.

V. TOOLS AND BEST PRACTICES FOR DESIGN DEVELOPMENT.


19. Design Failure Modes and Effects Analysis.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? The DFMEA Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. DFMEA Checklist and Scorecard. References.

20. Reliability Prediction.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? The Reliability Prediction Flow Diagram. Applying Each Block Diagram Within the Reliability Prediction Process. Reliability Prediction Checklist and Scorecard. References.

21. Introduction to Descriptive Statistics.
Where Am I in the Process? What Output Do I Get from Using Descriptive Statistics? What Am I Doing in the Process? Descriptive Statistics Review and Tools.

22. Introduction to Inferential Statistics.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get from Using Inferential Statistics? Inferential Statistics Review and Tools. References.

23. Measurement Systems Analysis.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Measurement Systems Analysis? MSA Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. MSA Checklist and Scorecard. References.

24. Capability Studies.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of a Capability Study? Capability Study Process Flow Diagram. Verbal Descriptions of the Application of Each Block Diagram. Capability Study Checklist and Scorecard. References.

25. Multi-Vari Studies.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? Multi-Vari Study Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Multi-Vari Study Checklist and Scorecard. Reference.

26. Regression.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? Regression Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Regression Checklist and Scorecard. References.

27. Design of Experiments.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of this Phase of the Process? DOE Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. DOE Checklist and Scorecard. Reference.

VI. TOOLS AND BEST PRACTICES FOR OPTIMIZATION.


28. Taguchi Methods for Robust Design.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Robust Design? The Robust Design Process Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Robust Design Checklist and Scorecard. References.

29. Response Surface Methods.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of RSM? RSM Process Flow Diagram. Verbal Descriptions of the Application of Each Block Diagram. RSM Checklist and Scorecard. Reference.

30. Optimization Methods.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Optimization? Optimization Process Flow Diagram. Verbal Descriptions of the Application of Each Block Diagram. Optimization Checklist and Scorecard. References.

VII. TOOLS AND BEST PRACTICES FOR VERIFYING CAPABILITY.


31. Analytical Tolerance Design.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Analytical Tolerance Design? The Analytical Tolerance Design Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Analytical Tolerance Design Checklist and Scorecard. References.

32. Empirical Tolerance Design.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Empirical Tolerance Design? The Empirical Tolerance Design Flow Diagram. Verbal Descriptions for the Application of Each Block Diagram. Empirical Tolerance Design Checklist and Scorecard. Reference.

33. Reliability Evaluation.
Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of Reliability Evaluations? The Reliability Evaluation Flow Diagram. Detailed Descriptions for the Application of Each Block Diagram. Reliability Evaluation Checklist and Scorecard. References.

34. Statistical Process Control. Where Am I in the Process? What Am I Doing in the Process? What Output Do I Get at the Conclusion of SPC? SPC Process Flow Diagram. Verbal Descriptions of the Application of Each Block Diagram. SPC Checklist and Scorecard. References.
Epilogue: Linking Design to Operations.
Appendix A: Design For Six Sigma Abbreviations.
Appendix B: Glossary 731
Index.

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Excerpts

Preface In its simplest sense, DFSS consists of a set of needs-gathering, engineering and statistical methods to be used during product development. These methods are to be imbedded within the organization's product development process (PDP). Engineering determines the physics and technology to be used to carry out the product's functions. DFSS ensures that those functions meet the customer's needs and that the chosen technology will perform those functions in a robust manner throughout the product's life. DFSS does not replace current engineering methods, nor does it relieve an organization of the need to pursue excellence in engineering and product development. DFSS adds another dimension to product development, called Critical Parameter Management (CPM). CPM is the disciplined and focused attention to the design's functions, parameters, and responses that are critical to fulfilling the customer's needs. This focus is maintained by the development team throughout the product development process from needs gathering to manufacture. Manufacturing then continues CPM throughout production and support engineering. Like DFSS, CPM is conducted throughout and embedded within the PDP. DFSS provides most of the tools that enable the practice of CPM. In this light, DFSS is seen to coexist with and add to the engineering practices that have been in use all along. DFSS is all about preventing problems and doing the right things at the right time during product development. From a management perspective, it is about designing the right cycle-time for the proper development of new products. It helps in the process of inventing, developing, optimizing, and transferring new technology into product design programs. It also enables the subsequent conceptual development, design, optimization, and verification of new products prior to their launch into their respective markets. The DFSS methodology is built upon a balanced portfolio of tools and best practices that enable a product development team to develop the right data to achieve the following goals: Conceivenew product requirements and system architectures based upon a balance between customer needs and the current state of technology that can be efficiently and economically commercialized. Designbaseline functional performance that is stable and capable of fulfilling the product requirements under nominal conditions. Optimizedesign performance so that measured performance is robust and tunable in the presence of realistic sources of variation that the product will experience in the delivery, use, and service environments. Verifysystemwide capability (to any sigma level required, 6s or otherwise) of the product and its elements against all the product requirements. DFSS is managed through an integrated set of tools that are deployed within the phases of a product development process. It delivers qualitative and quantitative results that are summarized in scorecards in the context of managing critical parameters against a clear set of product requirements based on the "voice of the customer." In short it develops clear requirements and measures their fulfillment in terms of 6s standards. A design with a critical functional response (for example, a desired pressure or an acoustical sound output) that can be measured and compared to upper and lower specification limits relating back to customer needs would look like the following figure if it had 6 sigma performance. The dark black arrows between the control limits (UCL and LCL, known asnatural tolerancesset at 1/2 3 standard deviations of a distribution that is under statistical control) and the specification limits (USL and LSL, known as VOC-based performance tolerances) indicates design latitude that is representative of 6 sigma performance. That is to say, there are 3 standard deviations of latitude on each side

Rewards Program