How to Use Tools to Enable
Lean Product Development
P2D2
I D
E
Kevin Otto
A
TDFQ
I2 D
O
V
DFQ
C D O V
PDSS
Center for Innovation in Product Development
MIT
1
Kevin Otto
v
Product Genesis Inc.
(www.productgenesis.com)
• Complete outsourced R&D
• Vice President, Leveraged Development
v
Product Development Systems
and Solutions Inc. (www.pdssinc.com)
• Focus on R&D improvement
• Principle Consultant
• TDFSS, DFSS Master Black Belt
v
Massachusetts Institute of Technology
• Previously Associate Professor of Mech. Eng.
• Center for Innovation in Product Development
PDSS
Center for Innovation in Product Development
MIT
2
My Perspective…
v
What does “lean” mean for product
development?
• Value stream mapping – right data
• Flow – flow of correct decisions
• No rework – stop undoing made decisions
v
Great. How do I do it?
• All the process mapping, restructuring, teaming
• Start enabling your engineers to provide options
• Stop your engineers from providing simply
single-point designs, requirements, ....
PDSS
Center for Innovation in Product Development
MIT
3
Part of the Value
The cost of fixing a single defect:
v $35 during the design phase
v $177 before procurement
v $368 before production
v $17,000 before shipment
v $690,000 on customer site
Mr. Hiroshi Hamada, President of Ricoh
Source: European Community Quarterly Review, Third Quarter 1996
PDSS
Center for Innovation in Product Development
MIT
4
R&D - Typical Phase Gate Development
(Cooper)
But really, there are three distinct activities happening
1. Product Portfolio Definition and Launch Planning
2. Technology Development
3. Product Commercialization
PDSS
Center for Innovation in Product Development
MIT
5
Screen Printer Industry
288
Cancelled
HIGH
3000
HiE
GENERAL
3000
265
LOW
2000
Competitor A
LOW
Portfolio configuration
impacts cost, not just
product configuration.
Medium - High Commonality
GENERAL
Low - Medium Commonality
Competitor B
HIGH
LOW
GENERAL
HIGH
3000
UltraFlex
Competitor C
High Commonality
PDSS
Center for Innovation in Product Development
MIT
6
Effective Research & Development
Product Portfolio Development
P2D2
I D
E
Product Commercialization
DFQ
C D O V
A
Product definitions
Technology definitions
Platform definition
Lean fast integration
Verification and Validation
TDFQ
I D
O V
Technology Development
Technology readiness
Robustness and scalability
PDSS
Center for Innovation in Product Development
MIT
7
Tools & Best Practices
You generate increased value through a
unique set of design & statistical tools…
v Tools that are focused on developing…
v
• the right DATA within each Phase of Product
Development!
• the right DATA to enable clarity in decision making
• the right DATA to reduce risk though identification
& management during Gate Reviews
PDSS
Center for Innovation in Product Development
MIT
8
Working the Systems Vee
Overall
Customer
Satisfaction
S
S
target
actual
Customer
Needs
System Simulation Models
System
Subsystems
Components
Ytarget
Systems
requirement
flowdown
y target
nestimated
Y = F(y,n,t)
Subsystem Technical Models
Subsystems
requirement
flowdown
y = f(x,n,t)
Component
adjustment
Component Technical Models
xtarget
nestimated
Component Development
PDSS
Yactual
Subsystem
adjustment
Center for Innovation in Product Development
MIT
y actual
nactual
xdesigned
nactual
9
CTF Metrics - Scorecards
CTF Output Variability
CTF Output (Y)
Design For Six Sigma Scorecard
Performance
Characteristic
Voltage
Units
V
Y/N
Y
Transfer Function
Formula (enter below)
2
Specification
Target
USL
2
2.1
Estimates Based on Mean Condition of x's and n's Listed Below
Predicted Performance Capability
6σ Score
σ -shift
LSL
mean: µ
s.d.: σ
Short/Long
Confidence
z
DPM
1.9
2 0.008654
11.55
0.00
0.0
x's, Input Control Factors
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Variables
Characteristic
X1
X2
X3
X4
X5
X6
I
Units
ohms
ohms
ohms
volts
ohms
ohms
amp
Range
Min
Max
20
2
2
1.2
2
500
50
50
30
50
Contribution to Variability
Sensitivity
%
0
0.00%
-0.3108194
32.03%
0.4176437
32.04%
0
0.00%
0
0.00%
0.7444038
32.04%
-10.449776
3.89%
Control factors (x)
PDSS
Specification
USL
LSL
Sample/Database Statistics
mean: µ
s.d.: σ
Short/Long
Confidence
20
0.04899
6.433029 0.015758
4.788771
0.01173
30
0.03873
2 0.004899
2.686714 0.006581
0 0.000163
z
-408.25
-408.25
-408.25
-774.60
-408.25
-408.25
0.00
6σ Score
σ -shift
Control factor Variability
Center for Innovation in Product Development
MIT
10
DPM
1000000.0
1000000.0
1000000.0
1000000.0
1000000.0
1000000.0
933192.8
Start with the Customer’s System
Manager
Handling of
Customers
Customers
Draw in
Credit
Phone
Approval
Customers
Approval
Customers
Advertising
Where is the value?
Credit Agency
Network
R e q for
payment
Incoming
Goods
Display
Stock Goods
Clerks
Goods
Shelf Space
Check Out
Customers
with goods
POS
Network
Goods
Clerk
Stock Drugs
Fill S c r i p s
Cash, check
Warehouse
R e -s u p p l y
Pharmacist
Bottling
Prescription
Supervisor
Revenue
daily totals
Transfers
Bag transport
Cash, check
Credit data
HQ/Bank
and credit
Daily Totals
Network
Added Revenue
Intervention
Tray transport
Network
Store Intercom
Order Goods
Backoffice
Items Sold
Data
N
f
Clerks
Network
CNfR (r2
R
r2
r1
CNfR (r
Reduced Expense
=
dollars
nRt
n Number
R Labor
of failures
rate per year
R Labor rate
t Time to deal with each failure
n Number
R Labor
of failures
rate
per year
t Time to deal with each failure
R Labor
t Time
rate to deal with each failure
t Time to deal with each failure
Center for Innovation in Product Development
MIT
r1 )
$9.00
r)
Reducedn Expense
Number of failures
= nRt per year
PDSS
−
C Average
N Number
customeroftransaction
customer transactions per year
dollars count
$9.00
600,000
C Average customer
transaction
=
2 − 1
dollars
$9.00
N Number
f Fraction
of customer
of customers
transactions
paying
per via
yeare-payment
count
percent
600,000
40%
N Number
Average
customer
of customer
transaction
transactions per year
dollars
count
$9.00
600,000
f Fraction
R Prime
of customers
Rate paying via e-payment
percent percent 40%
4%
f Fraction
Number
of customer
of customers
transactions
payingper
via year
e-payment
count
percent600,00040%
System reliability of bank-to-checkout
using
R Primer Rate
2
percent percent
4%
99.999%
Avaya
equipment
R Prime
Fraction
of customers
Rate
paying via e-payment
percent
40% 4%
System reliability
of bank-to-checkout
of bank-to-checkout
using percent
using
r 2 System
r 1 reliability
percent percent
99.999%
99.919%
Avaya
reliability
equipment
non-Avaya
of bank-to-checkout
equipment using
r 2 System
Prime
Rate
percent
99.999%
4%
Avaya
System reliability of bank-to-checkout using percent
r 1 equipment
$69
percent
99.919%
System
System
reliability
non-Avaya
reliability
of
bank-to-checkout
of
equipment
bank-to-checkout
using
using
r1
percent
percent99.999%
99.919%
Avayanon-Avaya
equipment
equipment
Reduced
Expense = nRt
$69
System reliability of bank-to-checkout using
percent
99.919% $69
non-Avaya
equipment
Reduced
Expense
n Number of
= failures
nRt per year
count
1
Added Revenue
C
Orders
=
C Average =
customer
(r2 − r1 )
Added Revenue
CNfR transaction
Added Revenue = CNfR (r2 − r1 )
$69
1$60.00
1
$60.00
6
count $/hr
$60.00
1
hr
6 $360
$/hr hr
$60.00 6
$360
Client Value of Avaya Solution:
$429
hr
6$360
count
$/hr
$/hr
hr
count
Client Value of Avaya Solution:
$360 $429
Client Value of Avaya Solution:
$429
11
Client Value of Avaya Solution:
$429
Identify Critical Customer Requirements
PDSS
Center for Innovation in Product Development
MIT
12
Develop Quality & Predictability through the
Identification & Measurement of Critical Functions…
Variation in Energy
Flow &
Transformations
Focus on variation
in the context of the
Laws of
Conservation of
Energy & Mass
WHAT exactly
do we measure?
Variation in Mass
Flow &
Transformations
These are leading
indicators of
reliability & quality
Variation in
Information Flow &
Transformations
“Statistical Engineering”
PDSS
Center for Innovation in Product Development
MIT
13
System Block Diagrams
… complete with flows of the physics!
Store
StoreRadar
Radar
Radar
*AC*
Deploy
Deploy
Radar
Radar
Radar
Sometimes above
Surface
*AC*
Warfighting Human
HVAC
Surface Air
Surface Air
Signal
Display
Display &
&
Control
Control
Contacts
Contacts
E M- S i g n a l
Transfer
Transfer
EM-Signals
EM-Signals
E M- S i g n a l
Filter/Process
Filter/Process
EM
EM-Signals
-Signals
*AC*
Inside Pressure
Hull
E M- S i g n a l
Heat
E M- S i g n a l
Open/Close
Open/Close
Water
Water &&
Pressure
Pressure Seal
Seal
Cooling Water
into Electronics
Freshwater
Cooling Water
fromElectronics
Hydraulic Forces
Seawater &
Acoustic Sig.
Forceinto
Seawater structure
Filter
Filter/ /
Process Ac.
Process
Ac.
Data
Data
Ac. Signal
Ac. Signal
*AC*
signal
sealed
Freshwater
Ac. Signal from
Active Sonar
Trans./Rec.
Trans./Rec.
Sound
Sound
Pulses
Pulses
Filter/Process
Filter/Process
ECM-Signals
ECM-Signals
ECM -S i g n a l
*AC*
Captain
Display
Display&&
Store
Store
Contacts
Contacts
WARFIGHTING
WARFIGHTING
CONTROL
CONTROL
*AC*
Display
Display&&
Control
Control
sealed Seawater
*AC*
ECMData
ECM-Data
*AC*
Transfer
Transfer
ECM
ECM-Signals
Signals
*AC*
Display
Display
classification
classification
data
data
Signal
*AC*
Store
Store
Periscope
Periscope
*AC*
Periscope
*AC*
Air from Airspace
Draginto
Seawater
*AC*
Warfighting
Human
HVAC
AC
Transmit/
Transmit/
Receive
ReceiveECM
ECM-Signals
Signals
ECM - S i g n a l
Drop In
*AC*
Ac. Signal
*AC*
Filter/Process
Filter/Process
Acoustic
AcousticData
Data
Ac. Signal
Transfer
Transfer
Data
Data
sealed Seawater
Display
Display&&
Store
Store
Contacts
Contacts
ac. signal
Ac.
Signal
Warfighting Human
HVAC
Opt. Signal
*AC*
Hold/Launch
Hold/Launch
Torpedo
Torpedo
Torpedo
*AC*
Transfer
TransferTo
To
Launch
Launch
Tube
Tube
*AC*
Interface
Interface
Human/Fire
Human/Fire
Control
Control
Signal
*AC*
Track
Track
Projectiles
Projectiles
Trajectory
Trajectory
Surface Air
Periscope
*AC*
Transfer
Transfer
ECMECM Signals
Signals
Opt. Signal
Open/Close
Open/Close
Water
Water &&
Pressure
PressureSeal
Seal
Surface Air
Store
Store
Torpedos
Torpedos
Torpedo
Display
Display&&
Control
-ControlIFF
IFF
Signals
Signals
Open
Openfor
for
Loading
Loading
Warfighting
Human
sealed Seawater
Antenna
*AC*
sealed
Surface Air
*AC*
Signal
Warfighting Human
HVAC
Deploy
DeployIFFIFFAntenna
Antenna
Antenna
*AC*
Transfer
Transfer
IFF-Signals
IFF-Signals
IFF- S i g n a l
*AC*
Interpret/
Interpret/
Process
-ProcessIFF
IFF
Signals
Signals
IFF-S i g n a l
Transfer
Transfer
IFF-Signals
IFF-Signals
IFF- S i g n a l
*AC*
Heat
Warfighting Human
HVAC
Open/Close
Open/Close
Water
Water &&
Pressure
PressureSeal
Seal
Surface Air
Antenna
IFF- S i g n a l
AC
Transmit/
Transmit/
Receive
ReceiveIFFIFFSignals
Signals
IFF-S i g n a l
*AC*
sealed
Surface Air
Surface Air
Signal
Torpedo
Torpedo
Control
Control
Signal
“Deploy
Weapon”
Interface
Interface
Human/Fire
Human/Fire
Control
Control(Mod.)
(Mod.)
Track
Track
Module
Module
Weapons
Weapons
*AC*
Sometimes above
Surface
*AC*
“Status”
Always under
Water
Air
Tracking Signal
Always under
Water
Distribute
Distribute and
and
Collect
CollectSignals
Signals
(Mod.)
(Mod.)
Force into structure
Transmit
Transmit
Force
Force
“Go To” Signal
*AC*
Module Signals
Humans
Materials
HVAC
Provide
Provide
Bulkhead
Bulkhead
Opening
Opening
Seal
SealSignal
Signal
aannddEEEE
Sealed
Seawater
Always under Water
Opt. Signal
Transmit/
Transmit/
Receive
ReceiveOpt.
Opt.&& Radio Signal
Radio
RadioSignals
Signals
Surface Air
Surface Air
IFF-S i g n a l
Air
Increase
Increase Air
Air
pressure
pressure
AC
Signal
*AC*
Torpedo
Store
-Store IFF
IFF
Antenna
Antenna
Periscope
Opt. Signal
*AC*
Warfighting Human
HVAC
Torpedo
Signal from/to Torpedo
Seawater.
A i r &T o .r
Deploy
Deploy
Periscope
Periscope
Heat
Warfighting Human
HVAC
Warfighting
Human
“Launch Torpedo” Signal
Seawater
Signal from/to
Torpedo
*AC*
Radio Signals
Seawater
Seal
SealTorpedo
Torpedo
Antenna
ECM - S i g n a l
Surface Air
Display
Display&&
Control Surf.
Control
Surf.
Contacts
Contacts
Radio
Radio
Control
Control
Seawater
Highpressured
air
Open/Close
Open/Close
Water
Water &&
Pressure
PressureSeal
Seal
Ac. Signal from
Passive Sonar
Heat
Torpedo
Signal from/to Torpedo
ECM - S i g n a l
sealed
Surface Air
HVAC
Noise, Vibration
Transfer
Transfer
ECMECM Signals
Signals
Heat
Cool
CoolAir
Airfor
for
Electronics
Electronics
Seal
SealSignal
Signal
aannddEEEE
Surface Air
Signal
ECM - S i g n a l
Warfighting Humans
Cooling Water
fromElectronics
*AC*
Ac. Signal
Surface Air
Antenna
*AC*
Warfighting Human
HVAC
Cooling Water
into Electronics
*AC*
Sense
SenseSignal
Signal
Deploy
Deploy
ECMECM Antenna
Antenna
Surface Air
E M- S i g n a l
E M- S i g n a l
Noise, Vibration
Deploy
DeployTowed
Towed
Array
Array
Array
Antenna
Warfighting Human
HVAC
Interpret
Interpret
acoustic
acoustic
signal
signal
*AC*
Noise, Vibration
Array
Store
StoreECMECMAntenna
Antenna
Transmit/
Transmit/
Receive
-ReceiveEM
EM
Signals
Signals
Ac. Signal
Freshwater
& Ac. Signal
Seal
Seal
Acoustic
Acoustic
Signal
Signal
*AC*
Warfighting Human
HVAC
Warfighting Human
HVAC
AC
sealed
Surface Air
Interpret
Interpret
acoustic
acoustic
signal
signal
ECM -S i g n a l
Transfer
Transfer
Data
Data
Ac. Signal
Heat
Store
Store
Towed
Towed
Array
Array
*AC*
Heat
Seal
Seal
Acoustic
Acoustic
Signal
Signal
Freshwater
Always under
Water
Signal
Radar
E M -S i g n a l
*AC*
Heat
Display
Display
classification
classification
data
data
Captain
Seawater &
Acoustic Sig.
Transfer
Transfer
EM-Signals
EM-Signals
*AC*
Warfighting Human
HVAC
Module Weight and Loads
Module/Underwater
Materials
HVAC
Humans
Seawater
*AC*
Module
Signals
Always under Water
Module/Underwater
Weld In
Modules
You have a mapping from top level requirements to these flows
Bolt On
PDSS
Center for Innovation in Product Development
MIT
14
Potential FMEA and RCA
SPT indicates vapor?
SV2 opens
Initialization
4 cylinders for n? seconds
SV1 open
SV4 closed
SV2 closed (delayed)
Engine starts
SPT indicates no vapor?
Ream of
Paper
Cooling
SV1 open
SV2 open
SV4 closed
SV4 closes
SV1 opens
SV2 closes
SV4 opens
SV1 closes
Ink Level
Indication
Jetted
Ink
Display
Status
Delivered
Print
Status
Indication
Jet Ink
SV2 open until HP2 says close
SV1 closed unless SPT says open (1 sec)
SV4 open
Ink
System Block Diagram
Store Ink
Heating
Vapors
SV1 closed
SV2 open until HP2 says close
SV4 open
Engine shuts down
SV4 closes
SV1 opens
Deliver and
Store Paper
Position Ink
Display Ink
Level
Defrost
Engine shuts down
SV4 closes
SV1 opens
Customer Needs
Increment and
Hold Paper
Process
Data
Input Data
SV4 opens
SV1 closes
SV4 closes
SV1 opens
SV2 opens
Pick Paper
Engine shuts down
SV2 closes
Shutdown
SV1 open
SV2 closed
SV4 closed
Load / Store
Paper
110/220V AC
Customer / Product States
Supply
Power
Remove Heat
Heat
Capture
Vapor
Filter Flow
Hot
Gases
Cool air
Item
Function
Potential Failure
Mode
Potential
Effect(s) of
Failure
S
e
v
C
l
a
s
s
Potential
Cause(s) of
Failure
O
c
c
u
r
Current Design
Controls
D
e
t
e
c
t
R
P
N
Recommended
Action(s)
0
Responsibility
and Target
Completion
Date
Action Results
Actions Taken
S
e
v
O
c
c
u
r
D
e
R
t t P
e
N
c
0
FMEA everything: business plan, requirements, concept, schedule, …
This generates requirements to metrics to models to ...
PDSS
Center for Innovation in Product Development
MIT
15
v
These require definition
• Fixed standards
• Exchange standards
v
Incorporate robustness
at the interface!
• Scalable parameters
• Robustness parameters
Paper Handling
x
Cartridge
Air Handling
Air Handling
Aligned
Paper
Paper
paper
advance
position
x
Jetted Ink
x
Print Handling
Electronics
Electronics
• Flows at boundary
• Attachments
Cartridge
Each module has
Paper Handling
v
Print Handling
Interface Definition
Paper
Ink
advance
commands
Cool air
Cool air
Cartridge
position
Paper
position
12 V
Cool air
x
Application Layer
Explorer, ftp, telnet
Presentation Layer
html, jpeg, mpeg
Session Layer
DNS
Transport Layer
TCP
Network Layer
IP
Data Link Layer
MAC
10BaseT
Center for Innovation in Product Development
MIT
Ink heat
x
Physical Layer
PDSS
Ink heat
16
Generate y=f(x) Relationships
Ream of
Paper
Load / Store
Paper
Pick Paper
Increment and
Hold Paper
Position Ink
Deliver and
Store Paper
Function
Insulate air
Contain Coffee
Contain Coffee
Import surface
Stabilize Forces
Insulate hand
Hold Coffee
Hold Coffee
Insulate air
Distribute Force
Delivered
Print
Jetted
Ink
Process
Data
Input Data
Ink Level
Indication
Display
Status
Status
Indication
Display Ink
Level
Jet Ink
Ink
Store Ink
Vapors
110/220V AC
Supply
Power
Remove Heat
Heat
Capture
Vapor
Filter Flow
Hot
Gases
Cool air
y
WT
Cooling Time
5
% Volume Lost
5
Delta Height
5
Base Width
5
Moment about Base 5
Boundary Temp.
4
Cup Volume
3
Cup Diameter
3
Coffee Temp
2
Hand Stress
2
Flow (M, E, or I)
Heat (E)
Coffee (M)
Coffee (M)
Surface (M)
Forces (E)
Heat (E)
Coffee (M)
Coffee (M)
Heat (E)
Hand (M), Force (E)
Y
Function
y
Insulate air
Cooling Time
flows
WT Flow (M, E, or I)
5
Heat (E)
x,n
A out
h out
M
M
M
M
Y
Element (Part)
Sidewall, Mouth, Lid
Side, Lid
Sidewall
Base
Base
Sidewall
Sidewall
Sidewall
Sidewall, Mouth, Lid
Sidewall, Mouth
A in
r out
r in
k cup h in
T coff T air m coff C p,coff
M
x’s and n’s
Now go model or experiment
PDSS
Center for Innovation in Product Development
MIT
17
Robust Design on Subsystems
y
Insulate air
Cooling Time
WT Flow (M, E, or I)
5
Heat (E)
x,n
A out
h out
M
M
M
M
A in
r out
r in
k cup h in
T coff T air m coff C p,coff
M
L1 2
1
2
3
4
5
6
7
8
9
10
11
12
Noise Factors
FUNCTION
NB
1
1
2
2
1
1
2
2
1
1
2
2
NC
1
1
2
1
2
2
2
2
1
2
1
1
ND
1
1
2
2
1
2
2
1
2
1
2
1
NE
1
1
2
2
2
1
1
2
2
1
1
2
NF
1
2
1
1
2
2
1
2
2
1
2
1
NG
1
2
1
2
1
2
2
2
1
1
1
2
NH
1
2
1
2
2
1
2
1
2
2
1
1
NI
1
2
2
1
1
2
1
1
2
2
1
2
NJ
1
2
2
1
2
1
2
1
1
1
2
2
NK
1
2
2
2
1
1
1
2
1
2
2
1
Y1
Y2
…
Yn
Ideal Output
8
Error States
Control Factors
y=f(x)
3
operating noise
(sones)
Input
NA
1
1
1
1
1
1
2
2
2
2
2
2
Wind noise potential
(dBA)
Function
7
6
2
1
0
5
new
new
limit
limit
after KLT
after KLT
1,8 Nm
random
nom. Pnl Posit.
worst case
2,8 Nm
… only then do reliability tests at the system level
PDSS
Center for Innovation in Product Development
MIT
18
Cognition Corp’s Six Sigma Cockpit:
Linking Critical Relationships
Project Level
Flow Down
Requirements
& CP Tree
Project Managed via
Sub-Team Groups
Provides scorecards at all levels
- System
- Subassembly
- Component
- Function
Cognition Corporation
PDSS
Center for Innovation in Product Development
MIT
19
Reinforce Data Based Gate Progression
Concept
Gate 2
Design
Gate 1
Gate 3
Optimize
Product Concept
Design Developed
Bus. Strategy, Family Plans. VOC,
Platform & Tech. Concepts
FMEA, Mod. Design, DOE
Modeling, MSA, …
Capability
Gate 4
Launch
Design Optimized
Design Capable
Robust Design, RSM
Sens. & Cap. Analysis,
Stress Testing, M-V
Critical
Critical Parameter
Parameter Management
Management
Scorecards help determine Phase advancement (Rank & Risk Assessment)
Gate 1
Item
Rank
Risk
Rank
Gate 2
Item
Score
Risk
Gate 3
Item
Score
Rank
Risk
Gate 4
Item
Score
Rank Approved
Risk
Score
Strategy
95
FMEA
95
Noise Char.
95
System Stress
Testing
95
Bus. Case
88
DOE & Models
88
Robust Design
88
Reliability
Assessment
88
Concept
Engineering
91
System Arch
91
Integration Plan
91
Capability
Analysis
91
Flexibility
91
Process CPM
91
DFQ Score
91.2
CPM
91
DFQ Score
91.2
6564
PDSS
6564
Analytical &
Exp. Sensitivity
91
DFQ Score
91.2
Center for Innovation in Product Development
MIT
6564
DFQ Score
6564
91.2
20
Areas to become Proficient
A
B
C
D
Overview &
Exercise
FMEA
&
Top-down
functional
RCA
Lean
Development
Process
&
Project Mgt.
VOC
Gathering
&
KJ Methods
DFMA
Design for
Lean
Production
Regression
Basic DOE
Reliability
Modeling
System
Variation
Stress Tests
PDSS
QFD
&
Reqts
Document
Methods
System
Architecting
Planning
Systems
Integration:
Design
Flexibility
and Risk
Pugh
Process:
Concept
Evaluation &
Selection
Model
Maturity
Assessment
Monte Carlo
Simulation
ANOVA
Critical
Parameter
Mgt.
Hypothesis
Testing
&
Confidence
Intervals
Measurement
Advanced
DOE
Robust
Design
&
Dynamic
Methods
Tolerance
Optimization
RSM &
Multiple Y
Optimization
Technology
& Process
Capability
Production &
Supply Chain
CPM
Statistical
Process
Control
DMAIC &
Lean
Production
Methods
Overview
ALT tests
HALT Tests
&
Warrantee
Guarantee
System
Analysis
Center for Innovation in Product Development
MIT
21
This Generates Results
ROI’s conservatively > 10X are typical
v Shorter time to market
v Improved Gate Decision Making
v Quality improvements
v Clarity of process
v
PDSS
Center for Innovation in Product Development
MIT
22