10. TTM Process (structured team-based problem solving) Motorola’s Six-Sigma Program Design for Manufacturability Program Xerox-based Baldridge Award criteria
26. Product Quality Data & Benchmarking We needed measurable and justifiable targets for new product quality
27. TDPU .027 95% 90% 97.3%** Industry Average Target Range -Old Products 100% PLANT FPY* Source: Industry Week 1998 World Class Performance Metrics Best in Class Target Range - New Products Below Industry Average 0 .05 .1 Plant Benchmark *First pass yield **True BIC=99.7% Median BIC= 97.3%
28. 2.6K 14.9K 1K I ndustry Average PPM Out of Box Benchmarks Source: Industry Week 1997 Benchmark Electronic Equipment companies over 1000 employees Best in Class Target Old Products Target New Products
29. 15K 4.2K Industry Average Target - New Products MTBF = 5 Years (18% Annual failure rate) MTBF = 20 Years (5% Annual failure rate) Warranty Benchmarks Monthly PPM Best in Class
30. 95% 90% 97.3% 100% PLANT FPY* Best in Class Target Range - New Products TDPU 0 . 027 .05 .1 1 YEAR Plant Benchmark — New Product Introductions *First pass yield
31. 2600 1K Best In Class PPM Out of Box Targets — New Product Introductions * Target New Products 3939 34% Reduction 6 Months *NPI curve developed by Dell
32. 4.2K 1K PPM Target New Products 5.6K 25% Reduction Warranty Targets — New Product Introductions 6 Months Best In Class
33. New Product DFM …(Preferred fastener set) Number of total fasteners in the system 4000 Number of fasteners active in the system 1200 Number of fasteners in original Preferred Set 74 Date Preferred Set was implemented July 1, 1998 Number of additions to the Set 2 Number of one-time exemptions to the Set 14