A O N

CONSULTING

6s
Define
DMADV for Processes and Services Define Project Charter and Mission

Create House of Quality and Scorecards

CTQs

CTQs

Design for Six Sigma

Functions.

Road Map
Identify Factors Critical to Success
Low Medium High

Design Elements

A well-defined charter and mission statement make sure the project is a good business investment, supports key business strategies, and adds true value for the customer
Risk Management Plan
Risk Financing unclear Test not ready Supplier not ready Category Action Check with Sponsor external testing status meetings Due June 17th Dec. 5th Aug. 3rd Resp. Status J. Williams completed I. Jacobson not started J. Williams pending

The QFD matrix is based on the VOC work to identify customer needs and priorities. A performance scorecard can be used at this stage to start tracking reliability

QFD 1

REQUIREMENTS FLOW Identify customer Functions needs Outline specifications Predict performance QFD

DFSS Product Scorecard Parts Score Process Score Software Score

VOC

Design Elements

Performance

We are here!

QFD 3

Process CTQs

QFD 4

Verify

Define

Design

Measure

Analyze

Failure to recognize and address a significant risk could jeopardize a project.

Customer Domain

Functional Domain

Map Voice of Customer to Voice of Process

Implementation Domain Control Domain

Service Development involves translating customer requirements into design elements and service process steps

Develop a Multi Generation Plan

An MGP helps you decide what needs to be done now and what should be done later

Analyze
Transport rider

How

Why
Dampen vibrations

Accommodate rider

Support Human body Apply Pedaling work

Develop Project Plans

Spending time up-front working with others in the organization to integrate the project plan is well worth the effort.
Qtr 1
Phase 1 Phase 2 Phase 3 Phase 4 Phase 5 Status Milestones

Generate movement

Transmit work

Convert pedaling work

Generate traction

CTQs

Measure
Understand the Voice of the Customer
The Voice of the Customer (VOC) describes customers needs and their perceptions of your product or service. Focusing on true customer benefit makes sure you are solving the right problem

Functions.

Qtr 2

Qtr 3

Qtr 4

Prioritize Functions

QFD 1
CTQs

VOC

Copyright 2002 Rath & Strong, a Division of Aon Consulting. All rights reserved.

Functions

QFD 2

Identify Key Functions

Design Elements

Prioritize functions from the customers perspective helps identifying valueadded features

QFD 3
Design Elements

Process CTQs

We are here!

QFD 4

Creating a solution-independent problem description is an essential step in the search for innovative solutions. Functional analysis is commonly accepted as best practice for this step

Sigma Level

Translate VOC into Measurable CTQs

Prioritized VOC needs are translated into measurable and testable characteristics.
DFSS_MAP_TECH_0303_V1

Generate, Evaluate and Select Concepts

Creativity techniques and Pugh matrices in a process of controlled convergence. Often concept generation is most successfully applied at the subsystem or component level.

Search

Generate

Screen

Combine, Generate, Prototype

Screen

Combine, Generate, Score Prototype

Product

6 5 4 3 2 1 A A B

C B

Project Goal

Concepts

A O N

CONSULTING

System FMEA
CTQs

SIPOC

Process FMEA

Faults DE
Functions

QFD 1
CTQs

VOC

VOC

xs

QFD 1
CTQs

Functions

Functions.

QFD 2
Functions.

Design Elements

Requirements Flowdown
Process CTQs Design Elements

Process Design
Process design closes the last gap in mapping VOC to VOP. In process design, we make a lot of very specific decisions on design elements already selected. This often includes issues of quality and cost optimization.

Design Elements

QFD 3

QFD 4

Design Matrix
We are here!

Requirements are flown down to more detailed specifications. At each level of detail functional requirements need to be mapped to design elements before proceeding to the next lower level.

QFD 2

Design Element s

QFD 3

DE

Design

I xs

O y

CTQs

Faults

Process CTQs

QFD 4

Systems Engineering
When designing complex systems the DMADV process is repeated at the next lower level for all new or critical design elements

We are here!
FR 1 DE 1

Voice of Customer
Measure

Customer Satisfaction
FR 11 FR 12 DE 11 DE 12

Verify
Hazard Rate - h(t) Early Life Failures Random-in-time Failures Wearo ut Failure s

Analyze
Requirements Flow Down

Design
System Integration

Verify
FR 111 FR 112 FR 113 DE 111 DE 112 DE 113

Predict Reliability
Predicting and improving reliability of involves lifecycle planning and reliability//availability simulation. Reliability of complex, repairable systems is improved by adding redundancy or optimizing spares.

FR 1131

FR 1132

DE 1131 DE 1132

Subsystems.. Modules.......... Components.... Assemblies...... Parts..................

M M M M M

A A A A A

D D D D D

V V V V V

Robust Design
Test design

Useful Life Period Bathtub Curve: Hazard rate over service life
Operating Time (t)

Define design

Concepts

Deliverables

Response Small Variance in Response

Copyright 2002 Rath & Strong, a Division of Aon Consulting. All rights reserved.

Big Variance in Response Factor Factor Setting A Factor Setting B

Sensitivity to variation can be reduced by using robust design approaches such as Dual Response Surface Methodology and Propagation of Error

Prototype / Pilot
The plan for collecting data during the pilot should be based on the Process Management Chart developed in Step 4: Develop Design. If the design goals have not been met, the team should choose to make another turn of the PDCA cycle, until design goals are met.
Act Plan

Flow Up Performance
DFSS scorecards facilitate bridging customer requirements with product and process performance at all stages. While the QFD process flows down overall requirements, scorecards flow up overall capability.

Y = f(X1, X2, ..,Xn)

Order Entry

Daily Pattern

Wait F or Confirmation

Obtain Confirmation

Check

Do

LINE OF VISIBILITY
Confirm Order

Order Processor Orders

Process Order

Order Transmittal

Validator

System
Subsystem

Order Transmittal

Implement

Order Transmittal

Subsystem

Subsystem

Subsystem

Simulate
Subsystem Subsystem

Zpart1, Zpart2,
Statistical ...parameters with mean values and variance

A simulation is an activity that allows one to draw conclusions about the behavior of a real (or proposed) process by studying the characteristics of a model. Use simulation to predict performance of process or product to determine if design is capable.

Design For Six Sigma DFSS Completed

With large complex implementations, there may be a final review after implementation has begun, and before the team is closed.

Full Implementation & Closure

Complete project documentation that summarizes results and learnings, and plan for celebrating your success.