
Training materials: Texts: Knowledge Based Management, Lean Six Sigma: A Tools Guide, Basic Statistics: Tools for Continuous Improvement, Understanding Industrial Designed Experiments; Software: SPC XL, DOE PRO, DFSS Master, SimWare Pro
Course agenda:
Introduction to Design for Six Sigma (DFSS)
• Comparing IDOV and DMAIC • The DFSS Opportunity • DFSS projects and studies • The Identify, Design, Optimize, Validate (IDOV) Methodology • Quantifying Savings and Benefits
Keeping Score
• Keeping Score using the DFSS Scorecard • Scorecard Elements and Construction • Parts • Process • Performance • Software • Methods for Computing DPU • Hands-on practice completing a DFSS Scorecard using DFSS Master Software
Voice of the Customer
• The Identify phase of IDOV • Determining Customer Wants and Needs • Survey Statistics • Identifying Critical to Customer Requirements • Prioritizing Customer Requirements • Introduction to Quality Function Deployment (QFD) and the House of Quality • Hands-on Practice Completing House of Quality #1 to identify Measurable CTCs (critical to customer measures)
Pugh Concept Generation and Selection, Systems Engineering, and Requirements Flowdown
• The Design phase of IDOV • Assigning Specs and Formulating Design Concepts • Overview of Triz and Axiomatic Design • Comparing Alternate Design Concepts using Pugh Concept Selection • Risk Analysis and Management • Building House of Quality #2
The Transfer Function
• Importance of Transfer Functions for IDOV • Methods for Obtaining Transfer Functions
Design for Robust Performance
• Concept of Deterministic vs. Probabilistic • Expected Value Analysis (EVA) for Quantifying the Distribution of the Output • Comparing Methods and Strategies for EVA • Root Sum Square (RSS) • Using Partial Derivatives • Worst Case Analysis • Monte Carlo Simulation • Using DFSS Master for EVA Analysis • Adding Noise to EVA • Working with Normal and Non-Normal Output Distributions • Robust Design: Finding Optimal Mean Settings for the Inputs to Minimize Variation in an Output • Hands-on Robust Design experiment using the Statapult® • Computer Based Robust Design (Parameter Design) using DFSS Master Software • Robust Design Exercises using SimWare Pro Software
Tolerance Allocation
• Quantifying the Sensitivity of the Output DPM to Changes in the Input Variable’s Standard Deviation • Tolerance Allocation Examples and Exercises • Setting Tolerances • Methods to Reduce the Standard Deviation of Inputs
Design for X-ability
• DFX Concepts – beyond just designing for performance • Design for Manufacturability vs. Design for Performance • Introduction to Design for Reliability (DFR) • Mistake Proofing and Error Proofing
Product Capability Prediction
• Updating the DFSS Scorecard and Making Predictions • Items to Consider for High DPU Elements
Test and Validate
• Sensitivity Analysis • Comparing Predicted Capability with Actual Performance • Gap Analysis • Control Plans
Stat-a-Copter Design Exercise
• Capstone Exercise: Hands-on practice with the IDOV process • Teams Design a Product to Meet the Customer Needs, using the IDOV process, complete with Optimization and Ultimately Limited Production and Testing of Their Design to Validate Performance
References and Course Evaluation Forms
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