Basic ideas and methods of DFSS

1. Presented by:
Mike Henderson
Business Performance Consultant
mrhenderson1105@gmail.com
Innovative Design: Design
for Six Sigma Primer

2. • Innovative design methods not well appreciated or
understood
• Design process not done via rapid learning cycles
• Design process not focused on Business Outcomes
• Design cycle driven by the budget cycle leading to
“firefighting”.
• Pre-determined Solutions short-circuiting innovation
2
Typical Issues Associated with
Innovation:

3. DFSS – (Design for Six Sigma) is a
systematic methodology utilizing tools,
training and measurements to design
products and processes that meet
customer expectations and can be
produced at Six Sigma quality levels.
3
Innovative Design:
Design for Six Sigma

4. 4
Why Design For Six Sigma?
RelativeCosttoMakea
DesignChange
1
10
100
1000
Research Design Implementation Operations Customer
DFSS focuses here
• “Design in” quality while costs are lowest.
• Customers experience six-sigma performance from the
start.

5. 5
DFSS Cycle
Identify Design
OptimizeValidate

6. 6
DFSS Cycle: Identification
• Voice of the Customer: Determining market
and customer unmet needs
• Customer Requirements
• Product or Process Differentiators
• Business Outcomes & Metrics
• Initial Project Plan

7. 7
DFSS Cycle: Identification Methods and
Tools
• Customer and Market research
• Value Stream Map
• SIPOC
• Current State Performance, Capability,
Reliability
• Target costing and benchmarking.

8. 8
DFSS Cycle: Design
• Critical Product & Process Parameters that
affect Customer Requirements
• Functional & Technical Requirements
• Risk & Failure Modes
• Specifications
• Evaluate Alternative Concepts

9. 9
DFSS Cycle: Design Methods and Tools
• Process Mapping
• System Diagrams
• Root Cause Analysis
• Transfer Functions
• FMEA
• PUGH Analysis
• Morphological Chart
• CTQ flow-down tree
• QFD
• Feasibility & Cost

10. 10
DFSS Cycle: Optimize
• Robust Design
• Risk and Failure Modes Analysis
• Environmental Conditions
• Sensitivity Analysis
• Proof of Concept

11. 11
DFSS Cycle: Optimize Methods and Tools
• Proof of Concept
• Prototypes
• Testing
• Simulation
• TRIZ
• Design of Experiments
• Capability Analysis
• Error Proofing
• Monte Carlo
• Six Sigma tools

12. 12
DFSS Cycle: Validate
• Proof of Concept on Selected Design &
Business Process
• Confirm performance, capability and
reliability
• Assess Over-all risk to Business
Outcomes in Operation
• Sustainability
• Final Review

13. 13
DFSS Cycle: Validate Methods and Tools
• Proof of Concept in Operation
• Confirm performance, capability and
reliability
• Asses Over-all risk to Business
Outcomes in Operation
• Controls and action plans

14. 14
Proof of Concept in Optimization and
Validation
Based on the uncertainty and relative risk involved,
various means to “prove” a solution’s ability to deliver
the desired Business Value can be used:
 The informed opinion of stakeholders and subject
matter experts
 Demonstration in operation elsewhere
 Low-fidelity prototypes (mock-ups)
 Product prototypes
 Product or process experimentation in varying
configurations and conditions
 Pilot (small scale) roll-out of a system into production

15. 15
Proof of Concept Principles
1. Well-defined objective: The objective of the proof of concept
study must be clearly defined regarding performance,
capability and reliability.
2. Sequential Approach: Rather than a large complex study,
rely on smaller more rapid learning cycles, with knowledge
gained in previous cycles used to design new studies.
3. Degree of Belief: Conclusions from the study should be
drawn with an adequate degree of belief. The study should
be conducted under a range of conditions to increase the
degree of belief that the results will hold in operation and
into the future.
4. Simplicity of Execution: The design of the study should be as
simple as possible, while still satisfying the first three
principles.