Design for six sigma training:

As we have already said, the approach of DFSS is quite different from the DMAIC model. Therefore, the training is also different. Fundamental issues for this training are:

• Understand and employ the DCOV process.

• Define and select a six sigma project for design, or redesign, of goods or services.

• Correlate customer needs with the specific features of a product or service.

• Analyze the potential effect of failures on the selected design.

• Achieve robust design levels that will function over the environmental areas of use.

Generally, the training for DFSS is of five-day duration, and it provides an overview of the six sigma approach to planning and design. The DCOV strategy emphasizes design for manufacturability of goods and/or the repeatability of services. Each phase is discussed together with the methods and tools typically used. A typical roll out follows the following steps:

• Explain the roles and responsibilities of the black belt, DFSS engineer and green belts in the DFSS process.

• Identify the DFSS training sequence for those involved in DFSS process sequence.

• Explain the DFSS, DCOV model/process.

• Demonstrate how the assessment measures the DCOV process.

• Identify the selection criteria for design projects.

Typical overall objectives of DFSS training are to:

• Apply coaching tools to support the engineering processes for DFSS.

• Select the appropriate customer satisfaction variables.

• Explain a transfer function and the relationship to improving customer satisfaction.

• Select the appropriate tools for applying the DCOV process.

• Explain robustness improvement strategies that will improve customer satisfaction.

• Identify resources available for assistance.

Specific training objectives for each phase of the DCOV model are as follows:

• Define. To capture the voice of the customer, trainees must learn to:

  • Establish the scope and goals of the project.

  • Develop the six sigma project plan.

  • Flow the macro process.

  • Describe the DCOV process and its associated steps.

  • Describe the relationship between DFSS activities and organizational timing.

  • Describe the relationship between DFSS and six sigma processes.

  • Establish balanced metrics.

  • Establish critical to customer metrics.

• Characterize. Trainees learn about system design, including how to:

  • Validate the measurement systems.

  • Identify process options that will satisfy customer requirements.

  • Identify weaknesses of the process actions.

  • Develop and understand the cause and effect matrix.

  • Employ statistics, experiments and observations to verify cause and effect.

  • Apply functional structure methods for flowing CTS big Ys down to lower level technical metrics, the small ys.

  • Determine critical little ys from list of technical metrics.

  • Select the appropriate tools for evaluating and generating new design concepts.

  • Explain evaluation criteria and assessment for this step.

• Characterize. Trainees learn about the functional mapping aspect of the DCOV model, including how to:

  • Determine method for relating little ys to critical to quality (CTQ) design parameters.

  • Describe how to flow little ys down to design parameters (xs) and noise factors (ns) using the transfer function.

  • Determine critical xs and ns.

  • Characterize robustness opportunities.

  • Explain evaluation criteria and assessment for this step.

• Optimize. Design for robustness is the topic of training for this aspect of the DCOV model. Trainees learn how to:

  • Characterize the present long time in service robustness for the product.

  • Select methods for improving product and process robustness by further minimizing product sensitivity to manufacturing and usage conditions—as required.

  • Explain the relationship of robustness and producibility.

  • Identify the appropriate tools to use when designing to be insensitive to variation.

  • Explain the process of robust assessment.

  • Explain the function, criteria for selection as a tool and interpretation of outputs of parameter design, tolerance design, statistical tolerancing and analytical reliability and robustness.

  • Explain the evaluation criteria and assessment for this step.

• Optimize. For the design for productivity function of the DCOV model, trainees must learn to:

  • Select process and product characteristics that will meet customer requirements.

  • Characterize capability and stability of present process.

  • Minimize process sensitivity to product and manufacturing variations—as required.

  • Explain the relationship of this step and the organization's milestone timing for product development as well as robustness.

  • Explain the purpose and selection criteria for determining the appropriate tools to make the product insensitive to noise.

  • Explain the purpose and selection criteria for each of the countermeasure tools as appropriate, including dynamic control plan, poka-yoke, sequence modeling and selective assembly.

  • Explain the evaluation criteria and assessment for this step.

• Verify. The verify step in the DCOV model involves assessment and testing, and training therefore focuses on how to:

  • Estimate sigma for process capability and product function at job one and over time.

  • Explain the evaluation criteria incorporated in the assessment.

  • Explain the use of the assessment in processing through the DFSS process.

  • Identify tools for assessing actual performance, reliability and manufacturing capability.

  • Explain what is meant by demonstrating customer correlated performance over time.

  • Explain the relationship between establishment of a transfer function, ys, xs and ns, and the development and execution of a quality design and verification plan.

  • Explain the evaluation criteria and assessment of this step.

  • Verify that the design can satisfy customer requirements.

Selected topics are covered in greater detail as needed. The typical content is:

• Why the DFSS approach is different.

• What does six sigma mean to a designer.

• Capability indices and their use.

• The DCOV strategy and when to apply it.

• How to define a six sigma project.

• Principles to apply in establishing metrics for a project.

• Correlating the voice of the customer with product features (QFD).

• The analysis phase and conceptual design.

• Concurrent design.

• Principles of experimentation.

• Statistical tolerancing.

• Concept of reliability.

• Decision matrices.

• Failure modes and effects analysis (FMEA).

• Fault trees.

• What constitutes an adequate pilot program.

• Planning for control.