Phong Q. Vo
Nov 30, 2012

Credentials
 B.A.Sci. in Mechanical Engineering, UW, 1989
 M. Eng.in Mechanical Engineering, UWO, 2003
 M.B.A., WLU, 2006
 Certified DFSS BB since 2007
 A member of PEO since 1993
 GM/GDLS employee since 1990, held various positions in engineering department (Design,
Computer Modeling & Simulation, Engineering
Quality, Systems Engineering)
 A good friend of Dr. P. Kurowski
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Topics of Discussion
 Definition of Quality
 What is 6 sigma?
 6 sigma benchmark
 Lean six sigma (LSS), Design For Six Sigma
(DFSS), Differences
 Phases in a DFSS project
 Structured Innovation & TRIZ
 Questions
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Definition of Quality



“A characteristic or attribute of something;
property; a feature” – The Houghton Mifflin
Canadian Dictionary
“Characteristic of a product or service that satisfies the customer's wants and needs in exchange for monetary considerations” -
Web definition
“High quality product or service can only be achieved by well/systematically designed process, disciplined execution, and the right attitude of the people involved” – P.Q.V.
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What is Six Sigma ?
 A disciplined, statistically driven methodology for eliminating or reducing defects (or waste) in any process.
 Originally developed by engineers at Motorola in the
1980’s to improve the company’s quality monitoring process.
 To day, the six sigma principles are used worldwide as a management tool to improve business outcomes.
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An illustration
StdDev = 3.2593
USL = 15
Sdffsdf
Sigma Level = 2.8991
Cpk = .9664
DPM = 3,564
N = 5 czx
Process to meet
In spec Sdfsdfsd
Out spec right
LSL sdffsdf
USL
Control Limits established to meet customer expectations
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6 Sigma Process Benchmark
Sigma Level
1 sigma
2 sigma
3 sigma
4 sigma
5 sigma
6 sigma
DPM
697,672
308,770
66,811
6,210
233
3.4
Assessment
Non-competitive
Non-competitive
Non-competitive
Industry Average
Industry Average
World Class
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What is Lean Six Sigma (LSS)?
 The application of lean six sigma philosophy to produce better products , at faster rates , and at lower costs .
 Lean means eliminating non-value added steps in a process.
 Six Sigma means reducing variation of a lean process.
In other words, the process produces no more than 3.4 defects per million.
 Synonymous with DMAIC (Define, Measure, Analyze,
Improve, Control)
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What is Design For Six Sigma
(DFFS)?
 A proactive, predictive, and systematic design approach to develop six sigma quality level products or services.
 Synonymous with DCOV (Define, Characterize,
Optimize, Validate)
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Main Differences between DFSS and LSS ?
LSS
Reactive identifies problems and modifies existing processes
Benefits are easy to quantify
Proactive
DFSS concentrates on up-front designs and processes
Benefits are long-term.
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Phases in a DFSS project
Define Characterize Optimize Validate
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Define Phase Define
 Voice of Customers (VOC)
 House of Quality #1
 CTC (Critical to Customers)
 Balance Scorecard (Parts, Process, Performance,
Software)
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Characterize Phase
Characterize
 Systems Engineering & Requirements Flow-down
 House of Quality #2
 Creation of Transfer Function (DOE, EVA)
 Design Concept Development
 Design Risk Assessment
 Design Concept Selection
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Optimize
Optimize
 Design for Robust Performance
 Tolerance Allocation
 Design for X (Manufacturability, Reliability,
Maintainability, Assembly, etc.)
 Product Capability Prediction
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Validate
 Prototype construction
 Predicted vs. Actual comparison
 Sensitivity Analysis
Validate
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Structured Innovation - TRIZ

TRIZ stands for “ Teoriya Resheniya
Izobreatatelskikh Zadatch” (A Russion acronym). It means “Theory of Inventive
Problem Solving”
 Genrich Altshuller, the father of TRIZ
 Born in Oct. 1926, in Tashkent, USSR
 Died on Sept. 24 th , 1998 in Petrozavodsk, Russia.
 An engineer, inventor, scientist, journalist, and writer.
 The story of G. Altshuller at Gulag concentration camp
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More on Altshuller & TRIZ
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More on Altshuller & TRIZ
 Altshuller screened over 200,000 patents and looked for patterns in problem solving techniques
 Altshuller concluded that
 There are a finite number of potential problems and solutions in the universe
 Innovation is a solution resolving major design conflicts (physical & technical contradictions)
 All problems can be framed within 39 parameters
 They can be solved using 40 principles
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Traditional Problem Solving Process
The
Wall
Problem A
Ideal
Solution
Traditional Problem Solving Process
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TRIZ Process
Problem A
TRIZ Process starts here
Ideal
Solution
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TRIZ Process
Specific
Problem
Generic
Problem
Specific
Solutions
Generic
Solution
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Questions
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