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