Design for Six Sigma
October 6th, 2016
Design for Six Sigma
IDDOV Cycle
Verify
Identify
Opportunity
Optimize
Design
Define
Customer
Requirements
Develop
Concepts
Design for Six Sigma
IDDOV Cycle
IDDOV – Identify problem, define customer needs, develop concepts,
optimize best concept, verify against other potential requirements
IDD – Identify problem, define customer needs, develop concepts, future
projects to follow to optimize if desired
IdOV – Identify problem, develop concepts, optimize best concept, verify
against other potential requirements
IOV – Identify problem,
already know desired concept, optimize chosen
Optimize
Design
concept, verify against
other potential requirements
RA (Robust Assessment) – Identify problem, assess concepts, select best
concept from the list, verify against other potential requirements
Design for Six Sigma
Identify Opportunity
Objective
Team
Business Case
Timing
Design for Six Sigma
Define Customer Requirements
“I want to
Drive Screws”
“I want to
open Paint
Cans”
“I want
to Stir
Paint”
How do you use
a screwdriver?
“I want one tool
to meet all of
my needs”
“I want an
easy way
to cut open
boxes”
“I want to borrow my Dad’s car”
“I want the door to stay open”
“I want to
pry things
apart”
Design for Six Sigma
Define Customer Requirements
We want to understand
how the Customer uses
our product so that we can
best meet their needs
Design for Six Sigma
Define Customer Requirements
Voice
Of
Customer
Engineering
Measures
Targets
Design for Six Sigma
Define Customer Requirements
Design for Six Sigma
Define Customer Requirements
KANO Model
Design for Six Sigma
Develop Concepts
Want to Avoid
“Voice of the Executive”
Design for Six Sigma
Develop Concepts
Use our knowledge of
Customer Wants to develop
“Winning” Concepts
“I want high quality sound”
“I want to listen
to my music
everywhere
I go”
“I want to carry all of
my music with me”
“I want to quickly select the
song I want to hear”
“I want my music to
play continuously”
Design for Six Sigma
Concept Generation Tools
TRIZ
Pugh / Decision Matrix
Morphological Matrix
Axiomatic Design
Design for Six Sigma
Develop Concepts
New
Ideas
Many,
Many
Concept
Ideas
 Criteria
Fewer
 Datum
Good
 Comparison Concepts
New
Ideas
Fewer
Better
Concepts
Combined
Ideas
Controlled Convergence
Combined
Ideas
1–2
Best
Concepts
Design for Six Sigma
Optimize Design
“Robust Optimization”
“Robust Engineering”
“Quality Engineering”
Definition of Robustness …
“The state of performance where the technology,
product or process is minimally sensitive
to factors causing variability,
at the lowest possible cost.”
Design for Six Sigma
8 Steps of Robust Optimization
1. Define Scope
2. Identify Ideal Function
3. Define Signal and Noise Strategy
4. Define Control Factors & Levels, and Choose Orthogonal Array
5. Conduct Tests & Collect Data
6. Analyze Data and Make Predictions
7. Confirm Predictions
8. Document and Plan to Verify &/or Tolerance Design
Design for Six Sigma
Optimize Design
Focus on Intended Function(s)
Create Heat
Emit Light
Support Shade
Mount to Lamp
Contain Vacuum
Electrical Energy In
Light bulb
“Emit Light”
Light Energy Out
Design for Six Sigma
Optimize Design
100
60
Electrical Energy In
Light Energy Out
Emit Light
“Conservation of Energy”
Symptoms of Poor Performance
25
10
25
Heat
5
20
5
Vibration / Noise
10
Wear / Shorter Life
“Whack-A-Mole Engineering”
Design for Six Sigma
Optimize Design
Light Energy
β2
S/N = 10 log
σ2
Line of Best Fit with slope β
σ
Electrical Energy
Design for Six Sigma
Light Energy
Optimize Design
Taguchi 2-Step
Optimization :
1. Reduce
Variability due to
effects of Noise
2. Adjust β
Electrical Energy
Design for Six Sigma
Optimize Design
NOISE FACTORS
“All the ways that our Customers will use
and abuse our products …”
All Factors which effect the function of our
design which we have, or choose to have,
no control over
DFMEA
DVP&R
Design for Six Sigma
Optimize Design
Inner Noise
•
•
•
•
Aging
Deterioration
Wear
Corrosion
Outer Noise
• Environmental Conditions
• Operating Environment
• Neighboring Subsystems
Between Product Noise
• Manufacturing Variability
• Stack Up Tolerance
Noise
Factor
N1
N2
A
Age
1000
hours
New
B
Ambient
Temp
-20 F
Ambient
C
Manuf.
Variation
Low
High
Design for Six Sigma
y : Output Response
Optimize Design
M1
M2
M3
X y5
N2
X y6
N1
X y3
X y1
X y4
X y2
105 V
120 V
135 V
M : Input Signal
Design for Six Sigma
Optimize Design
Control Factors = All Factors which affect the Function of
our design that we DO have control over …
A
B
C
E
D
F
G
H
Control Factor
Level 1
Level 2 *
Level 3
A Glass Bulb Shape
Oval
Circle
B LP Inert Gas
Gas 1
Gas 2
Gas 3
C Filament Material
Material 1
Current
Low Cost
Alternative
D Contact Wire Material
Material 1
Current
Material 2
E Contact Wire Gage Size
Smaller
Current
Larger
F Support Wire Gage Size
Smaller
Current
Larger
G Stem Shape
Triangle
Circle
Square
H Cap Material
Material 1
Current
Lighter Material
Design for Six Sigma
Inner Array
L18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
A
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
B
1
1
1
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3
C
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
D
1
2
3
1
2
3
2
3
1
3
1
2
2
3
1
3
1
2
E
1
2
3
2
3
1
1
2
3
3
1
2
3
1
2
2
3
1
F
1
2
3
2
3
1
3
1
2
2
3
1
1
2
3
3
1
2
G
1
2
3
3
1
2
2
3
1
2
3
1
3
1
2
1
2
3
H
1
2
3
3
1
2
3
1
2
1
2
3
2
3
1
2
3
1
Design for Six Sigma
Inner Array
L18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
A
Oval
Oval
Oval
Oval
Oval
Oval
Oval
Oval
Oval
Circle
Circle
Circle
Circle
Circle
Circle
Circle
Circle
Circle
B
Gas 1
Gas 1
Gas 1
Gas 2
Gas 2
Gas 2
Gas 3
Gas 3
Gas 3
Gas 1
Gas 1
Gas 1
Gas 2
Gas 2
Gas 2
Gas 3
Gas 3
Gas 3
C
Material 1
Current
Low Cost
Material 1
Current
Low Cost
Material 1
Current
Low Cost
Material 1
Current
Low Cost
Material 1
Current
Low Cost
Material 1
Current
Low Cost
D
Material 1
Current
Material 2
Material 1
Current
Material 2
Current
Material 2
Material 1
Material 2
Material 1
Current
Current
Material 2
Material 1
Material 2
Material 1
Current
E
Smaller
Current
Larger
Current
Larger
Smaller
Smaller
Current
Larger
Larger
Smaller
Current
Larger
Smaller
Current
Current
Larger
Smaller
F
Smaller
Current
Larger
Current
Larger
Smaller
Larger
Smaller
Current
Current
Larger
Smaller
Smaller
Current
Larger
Larger
Smaller
Current
G
Triangle
Circle
Square
Square
Triangle
Circle
Circle
Square
Triangle
Circle
Square
Triangle
Square
Triangle
Circle
Triangle
Circle
Square
H
Material 1
Current
Lighter Material
Lighter Material
Material 1
Current
Lighter Material
Material 1
Current
Material 1
Current
Lighter Material
Current
Lighter Material
Material 1
Current
Lighter Material
Material 1
Design for Six Sigma
Inner and Outer Array
L18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
A
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
B
1
1
1
2
2
2
3
3
3
1
1
1
2
2
2
3
3
3
C
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
D
1
2
3
1
2
3
2
3
1
3
1
2
2
3
1
3
1
2
E
1
2
3
2
3
1
1
2
3
3
1
2
3
1
2
2
3
1
F
1
2
3
2
3
1
3
1
26
2
3
1
1
2
3
3
1
2
M1
N1 N2
y1 y2
G
H
1
1
2
2
3
3
3
3
1
1
2
2
2
3
3
1
1
2
conditions
x 18
2
1
3 = 2108 Tests
1
3
3
2
1
3
2
1
1
2
2
3
3
1
M2
N1 N2
y3 y4
M3
N1 N2
y5 y6
Signal Strategy
Noise Strategy
runs
If you ran full factorial it would be 4374 RUNS
If you didn’t compound noises it would be 78,732 samples
Design for Six Sigma
Inner and Outer Array
Design for Six Sigma
Verify
Document
Test
Requirements
Integrate
Implement
/ Launch
Design for Six Sigma
When Do I Use The Tools
Proactive Quality Product Development Process
Employ Proactive Tools and Methods that:
•
Define Engineering Measures to meet Voice of the Customer (VOC).
•
Develop concepts that meet VOC, Regulatory, etc.
•
Deliver Robust Systems and Components.
Decoupled
Pre-coupled
Features
Feed Back
Reactive Problem Solving:
A Structured, Disciplined, Statistical Approach to Problem Solving
•
Shainin Red X Strategies.
•
Kepner-Tregoe.
•
Statistical Basics.
Design for Six Sigma
Example
Make the Seat Structure Lighter
Reduce Gauge
Functions
Support Occupant
Insulate NVH
Different Geometry
Durability Performance
Crash Protection
Lighter Material
Maintain or Improve
performance of these
Functions !!
FCA DFSS Supplier Program
Strategic Vision
The Goal of the FCA DFSS Supplier Program is to encourage the use of
DFSS as an extension of PDP (Product Development Process)
Expectations of Supplier (consistent with our own):
1 ) Have DFSS Program be part of your product development process, including;
 Deployment Champion, Training Plan, Project Selection Process, Coaching Capability
2) Utilize the DFSS Methodology / Tools when Defining Function Requirements, such as;
 VOC (QFD), HOQ (House of Quality), Function Mapping, etc….
3) Utilize the DFSS Methodology/Tools when Selecting Design Alternatives, such as;
 Triz, Axiomatic Design, Innovation Techniques, Pugh & Decision Analysis,
Morphological Matrix, etc…
4) Utilize DFSS Methodology, Techniques when Optimizing Designs, such as;
 Ideal Function, Energy Thinking, Noise Strategy, Taguchi Optimization
5) Supplier Resources assigned to FCA are Capable of Supporting / Leading DFSS Projects;
 At appropriate skill level; Green Belt, Black Belt, Master Black Belt, as required
FCA DFSS Supplier Program
What Are The Different Types Of Projects
“Co-Led” DFSS Projects are a Win-Win for FCA & Supplier!
 Robust Engineering / Proactive Product Development
 Supplier / FCA Collaboration on System & Component Development
 DFSS Skill Set Development
FCA DFSS Supplier Program
How Do I Get Involved
We want to participate in the DFSS Initiative, how does a Supplier get involved?
 Contact your Systems & Component (S&C) Engineering Team; seek out their DFSS Experts.
 Contact Neill Quinlan (FCA Supplier Deployment Champion)
 Contact Jodi Robinson-Emmerich (Program Coordinator) and get connected to the DFSS
Supplier Program SharePoint Site for information on getting started
How does a Supplier get DFSS Training or Coaching?
 Grow / Hire-In the Expertise
 Leverage 3rd Party Consultants (FCA utilizes ASI, Suppliers can get discounts, as part of the
FCA Supplier DFSS Program)
Will FCA Train / Coach Suppliers?
 FCA does not pay for the Supplier DFSS Training
 FCA does coach DFSS Projects that are “Co-Led” in cooperation with S&C Engineering (this
is a great way to get started!).
FCA DFSS Supplier Program
Contact Information
Systems & Components DIS Contact Names
(DFSS Implementation Specialists)
Advanced Development - Krzysztof Michalowski
(chris.michalowski@fcagroup.com)
Body Engineering – Dan Gutowski
(daniel.gutowski@fcagroup.com)
Electrical Engineering – Mary Clor or Renee Cole
(mary.clor@fcagroup.com or renee.cole@fcagroup.com)
Chassis Engineering – Bo Zhang
(bo.zhang@fcagroup.com)
Interior Engineering – James Shipton
(james.shipton@fcagroup.com)
Powertrain Engineering – Antonio Pedini
(antonio.pedini@fcagroup.com)
Restraints Engineering – Jim Webber
(jim.webber@fcagroup.com)
Engine Systems – Phil Lewis
(phillip.lewis@fcagroup.com
FCA DFSS Supplier Program
Contact Information
Supplier DFSS Deployment Champions at FCA:
Neill Quinlan
DFSS MBB Candidate
(248) 576 – 4261
neill.quinlan@fcagroup.com
Jodi Robinson-Emmerich
SharePoint access and connection
jodi.robinson-emmerich@external.fcagroup.com
Training / Coaching Consultants:
ASI Consulting Group LLC*
Jodi J. Caldwell
30200 Telegraph Road, Suite 100
Bingham Farms, MI 48025
Tel: (248) 530-1395
jodi.caldwell@asiusa.com
* Although you make seek training alternatives, ASI is the consultant FCA uses, if you choose alternative
training we may wish to understand the depth and breadth of the knowledge covered in the training
Q&A