Design For Six Sigma - Robust and Tolerance

January 2002
6σ
Design for
Six Sigma
. Example of Robust and Tolerance Design
Pier Giorgio DELLA ROLE
Dfssexample1.ppt 1
Example of DFSS for a subsystem
We are faced with the task of designing a pump capable of delivering

a constant flow rate of 10 l/min. Customer requires a pump with
‘6 sigma’ performance with a flow rate between 9 and 11 l/min.
Control
Factors
. Radius 11 l/m
. Stroke length Performance
. Backflow Pump Flow rate = 10 l/m (target)
. Motor speed
(rpm) 9 l/m
Noise Factor
Manufacturing
variation
2
Functional Scheme and Transfer Function Y = f (x)
One way
valve Tubing
Flow rate (l/min)
2
F = (3.141 x R x L - B) N
R = Piston radius
L = Stroke length
B = Back flow
N = Motor speed (rpm)
Piston
3
PROCEDURE FOR SETTING TARGETS and TOLERANCES
1. It may be possible to reduce the output’s variation by

adjusting the average of the inputs
( non linear relationship between inputs and output)
Adjusting the averages can make the pump less sensitive or more ROBUST
to the variations of the inputs.
Since it is generally less costly to adjust targets than tighten tolerances,
this step has the highest priority.
2. If the desired performance has not been achieved, the next

step would be to tighten tolerances.
The question is which tolerances and by how much?
In deciding which tolerances to tighten, you should consider

both the cost and the effect of change.
4
DATA for DESIGN and MANUFACTURING PROCESSES
Factors Nominal value Dev. Standard
Radius 0.4 dm 0.2 dm 0.001

MAKE
From the actual

manufacturing
process
Stroke length 0.4 dm 0.8 dm 0.002
Back flow 0.002 l 0.002 l 0.00005 0.00002

BUY
(Inlet Valve)
N (rpm) 50 100 2 1
(Electrical motor)
Low cost High cost
Solution 1 Solution 2
5
MonteCarlo Simulation
How much variation in Y (output) is created by variation in X (inputs)
and the system function Y = f (X)
Y
Y = f(X)
. Random values of X are generated and applied to function Y = f (X)

to predict the variation of Y
. Transfer function Y = f(X) can be non-linear
. X’s can be any distribution
. May require a lot of trials (~1000) and results are not repeatable
6
Flow rate - Solution 1
Process Capability Analysis for Flow rate
LSL USL
Process Data
USL 11,0000 ST
Target * LT
LSL 9,0000
Mean 9,9572
Sample N 200
StDev (ST) 0,406053
StDev (LT) 0,406053
Potential (ST) Capability

Cp 0,82
CPU 0,86
CPL 0,79
Cpk 0,79
Cpm * 8,5 9,0 9,5 10,0 10,5 11,0 11,5
Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance

Pp 0,82 PPM < LSL 5000,00 PPM < LSL 9200,66 PPM < LSL 9200,66
PPU 0,86 PPM > USL 5000,00 PPM > USL 5114,07 PPM > USL 5114,07
PPL 0,79 PPM Total 10000,00 PPM Total 14314,73 PPM Total 14314,73
Ppk 0,79
7
Flow rate - Solution 2
Process Capability Analysis for Flow rate2
LSL USL
Process Data
USL 11,0000 ST
Target * LT
LSL 9,0000
Mean 9,8638
Sample N 200
StDev (ST) 0,221539
StDev (LT) 0,221539

Cp 1,50
CPU 1,71
CPL 1,30
Cpk 1,30
Cpm *
9,0 9,5 10,0 10,5 11,0

Ppk 1,30
8
Process Capability Analysis for Flow rate
LSL USL
Process Data
USL 11,0000 ST
Target * LT
LSL 9,0000
Mean 9,9572
Sample N 200
StDev (ST)
StDev (LT)
0,406053
0,406053
Comparison between solution 1
and solution 2.
Cp 0,82
CPU 0,86
CPL 0,79
Cpk 0,79
Cpm * 8,5 9,0 9,5 10,0 10,5 11,0 11,5

Ppk 0,79
LSL USL
Process Data
We have achieved a ROBUST USL 11,0000 ST
LT
design NOT by changing the Target
LSL
*
9,0000
tolerances on the parameters, Mean

Sample N
9,8638
200
but by changing only their StDev (ST)

StDev (LT)
0,221539
0,221539
nominal values.
Robustness is obtained by designing Cp 1,50
CPU 1,71
a pump to be less sensitive to the CPL 1,30
Cpk 1,30
variation of the inputs. Cpm * 9,0 9,5 10,0 10,5 11,0
The inputs continue to vary, but less Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance
of this variation is transmitted to the Pp

PPU
1,50
1,71
PPM < LSL
PPM > USL
0,00
0,00
PPM < LSL
PPM > USL
48,30
0,15
PPM < LSL
PPM > USL
48,30
0,15
output. PPL
Ppk
1,30
1,30
PPM Total 0,00 PPM Total 48,44 PPM Total 48,44
9
QUALITATIVE CONSIDERATIONS
Volume Robustness achieved

in solution 2 (compared to
solution 1) is due to the
L = cost. non linear relationship
between ‘radius’ and
‘volume’.
The input (radius) continues

to vary , but less variation is
transmitted to the output
(volume).
Radius
10
What if the desired performance has not been achieved?
Flow Rate
Contribution
to total
variation
N R L B Total
Inputs
The next step would be to tighten tolerances. This generally requires using more
expensive components and processes.
The question is which tolerances and by how much?
11
Flow rate (l/min)
Best Subsets Regression
2
P = (3.141 x R x L - B) N
Response is Flowrate
R = Piston radius
B L = Stroke length
a B = Back flow
R L c N = Motor speed (rpm)
a e k
d n -
i g f
Adj. u t l One way
Tubing
Vars R-Sq R-Sq C-p s s h o N valve
1 78,7 78,6 6E+05 0,10767 X

1 28,7 28,4 2E+06 0,19703 X
2 98,7 98,7 4E+04 0,026508 X X
2 80,2 80,0 6E+05 0,10416 X X
3 99,9 99,9 1297,5 0,0052753 X X X
3 98,8 98,8 4E+04 0,025855 X X X
4 100,0 100,0 5,0 0,0019136 X X X X
Piston
The motor speed (N) is responsible for 78,6% of the
total variation of the output (flow rate)
12
DATA for DESIGN and MANUFACTURING PROCESSES
Factors Nominal value Standard Dev.
Radius 0.4 dm 0.2 dm 0.001

MAKE
From the actual

manufacturing
process
Stroke length 0.4 dm 0.8 dm 0.002
Back flow 0.002 l 0.002 l 0.00005 0.00002

BUY
(Inlet Valve)
N (rpm) 50 100 2 1
(Electrical motor)
Low cost High cost
Data used for solution 3 13

Flow rate - Solution 3 (Achieved by reducing the variation of motor speed)
LSL USL
Process Data
USL 11,0000 ST
Target * LT
LSL 9,0000
Mean 9,8424
Sample N 200
StDev (ST) 0,144828
StDev (LT) 0,144828

Cp 2,30
CPU 2,66
CPL 1,94
Cpk 1,94
Cpm *
9,0 9,5 10,0 10,5 11,0

Ppk 1,94
14

Design For Six Sigma - Robust and Tolerance

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January 2002

Pier Giorgio DELLA ROLE

We are faced with the task of designing a pump capable of delivering

1. It may be possible to reduce the output’s variation by

2. If the desired performance has not been achieved, the next

The question is which tolerances and by how much?

In deciding which tolerances to tighten, you should consider

Factors Nominal value Dev. Standard

Radius 0.4 dm 0.2 dm 0.001

From the actual

Back flow 0.002 l 0.002 l 0.00005 0.00002

. Random values of X are generated and applied to function Y = f (X)

Process Capability Analysis for Flow rate

Potential (ST) Capability

Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance

Process Capability Analysis for Flow rate2

Potential (ST) Capability

Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance

Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance

tolerances on the parameters, Mean

but by changing only their StDev (ST)

of this variation is transmitted to the Pp

Volume Robustness achieved

The input (radius) continues

1 78,7 78,6 6E+05 0,10767 X

Factors Nominal value Standard Dev.

Radius 0.4 dm 0.2 dm 0.001

From the actual

Back flow 0.002 l 0.002 l 0.00005 0.00002

Data used for solution 3 13

Process Capability Analysis for Flow rate3

Potential (ST) Capability

Overall (LT) Capability Observed Performance Expected ST Performance Expected LT Performance

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