design for six sigma(DFSS).pdf

DFSS 2010/9/18 ? 2010 by Albert H.C. Tsang 1 Design For Six Sigma (DFSS) Dr. Albert H.C. Tsang Phone:2766 6591 Fax: 2362 5267 email: albert tsang@polyu edu hk. . . Design For Six Sigma (DFSS) A systematic methodology with tools, training measurements which enable us to design products/processes that meet customer expectations and can be produced at the 6? level ? 2010 by Albert H.C. Tsang DFSS 2 DFSS 2010/9/18 ? 2010 by Albert H.C. Tsang 2 Communication Breakdown in a Product Development Process ? 2010 by Albert H.C. Tsang DFSS 3 Most Quality Problems are Designed In Manufacturing Defects: 20 – 30% Relative cost / difficulty to correct quality problems money spent Designed in Quality Problems: 70 – 80% ? 2010 by Albert H.C. Tsang DFSS 4 concept prototyping requirements design production DFSS 2010/9/18 ? 2010 by Albert H.C. Tsang 3 Developing a Robust Design Major Elements: Process Capability CTQ Identification Tolerance Analysis ? 2010 by Albert H.C. Tsang DFSS 5 ROBUST DESIGN One Approach to Achieving Six Sigma Develop Team Team Charter Gather VOC CompetitiveAnalysis QFD Develop CTQs 1 Identify D i Identify functional requirements Develop alternative concepts Evaluate alternatives and select best-fit concept Deploy CTQ’s and predict sigma capability Develop detailed design elements Predict Performance Identify Gap 2 3 Optimize Design es gn Optimize ? 2010 by Albert H.C. Tsang DFSS 6 Pilot Plan Review Implementation Plan Control Plan Continuous Improvement 4 Validate DFSS 2010/9/18 ? 2010 by Albert H.C. Tsang 4 Identify (Measure) Phase 1 Identify Customer/Product Requirements Identify Technical Requirements (CTQ Variables) and Limits Key Tools ? QFD ? FMEA ?Target Costing ? Benchmarking ? 2010 by Albert H.C. Tsang DFSS 7 Linking design to Voice of the Customer CTQ Identification ? What is Critical-to-Quality? The select few, measurable key characteristics of a specific part/process/specification that must be in statistical cont