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Chapter 12---Part 3 Six Sigma and Technical Systems

Design

for Six Sigma (DFSS) represents a set of tools and methodologies used in the product development process. It ensures that goods and services will meet customer needs and achieve performance objectives, and that the processes used to make and deliver them achieve Six Sigma capability. DFSS consists of concept development, design development, design optimization, and design verification.

Quality

Function Deployment (QFD) is a planning process to guide the design, manufacturing, and marketing of goods by integrating the voice of the customer throughout the organization.

set of matrices is used to relate the voice of the customer to a products technical requirements, component requirements, process control plans, and manufacturing operations. The first matrix, the customer requirement planning matrix, which is often called the House of Quality, provides the basis for the QFD concept.

Interrelationships

Technical Requirements Relationship between customer requirements and technical requirements Priorities of Technical requirements

Voice of the customer

Priorities of Customer
requirements

Competitive Evaluation

TOOLS FOR PROCESS IMPROVEMENT

Numerous methodologies for improvement have been proposed over the years. These include the Deming cycle, FADE (Focus, Analyze, Develop, and Execute), Jurans breakthrough sequence, and creative problem-solving. How one approaches problem solving is not a critical as doing it in a systematic fashion.

The Deming cycle is a problem-solving methodology that consists of four elements: plan, do, study, and act It is based on management by fact, continuous improvement, and organizational learning principles and has had much success in Japanese companies prior to being adopted throughout the world.

Plan

Act

Do

Study

Define the process: its start, end and what it does. Describe the process: list key tasks, people involved, equipment used, work methods etc Describe the players Define Customer expectations. Determine what historical data is available and what needs to be collected. Describe the perceived problem---with the process, failure to c.meet Expect. Variation. Identify primary causes Develop potential changes Select most promising solution.

Conduct

a pilot study to test the impact of potential solutions. Identify measures to understand how any changes or solutions are successful in addressing the perceived problem.

Examine

the results of the pilot study or experiment. Determine whether process performance has improved. Identify further experimentation that may be necessary.

Select

the best changes or solutions. Develop an implementation plan. Standardize the solution for example by writing new standards operating procedures. Establish a process to monitor and control process performance.

Jurans breakthrough sequence consists of proof of the need, project identification, organization for breakthrough, the diagnostic journey, the remedial journey, and holding the gains. These steps represent a common sense sequence of discovery, organization, diagnosis, corrective action, and control.

The

creative problem solving process consists of six steps: understanding the mess, finding facts. identifying specific problems, generating ideas, developing solutions, and implementation.