Target USL LSL Centered Process Reduced Spread Defects Objective of Capability Understand and Reduce Variation / Center Process Customers Feel Variation Through Product Performance Process Off Target Target USL LSL Excessive Variation Target USL LSL
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Target
USLLSL
CenteredProcess
ReducedSpread
Defects
Objective of Capability
Understand and Reduce Variation / Center ProcessCustomers Feel Variation Through Product Performance
Process Off TargetTarget
USLLSL
Excessive VariationTarget
USLLSL
Top Level QualityDPU / DPMO (Cpk)
ProcessWhat Process Quality Level
is Required for Design?
PerformanceHow Robust Should the
Design be for Normal Variation?
PartsWhat Component
Quality Level is Needed for the Part Design?
SoftwareWhat Software Quality
Level is Required?
ReliabilityWhat Performance Can be
Expected Over time?
Elements of Capability
Short and Long-Term Capability
EXAMPLE:
A System With 5 CTQ’s at Cpk of 1.33 / the quality level would be:
(0.99994)^5 = 99.97% or a Total Defect Level of 300 PPM (w/out process shift)
As More Variation Is Introduced (material, machine, man etc.) the Process Will Shift, The True Quality Level Would Be: (0.9938)^5 = 96.34 or a Total Defect Level of 36,000 PPM!!
Short-Term(Cpk)
(Validation)
Long-Term(Ppk)
(Production)
Process and Common Cause VariationProcess and Common Cause Variation
Typical Process Capability Journey
DevelopmentManufacturing
(Production Environment)
Time
Cpk Target
1.0
0.5
1.0
0.5
Cpk (CTQ’s)
Cpk “Growth” During Development
Cpk “Peaks”Validation Runs
Variation Sets In
- 0.75
Ppk (CTQ’s)
Stage 2 Stage 3 Stage 5 Stage 4 Stage 1
Design for Six Sigma & Sustaining Capability
Predictive Design Quality
Transition to ...
Reactive Design Quality
“Test in” Quality
Evolving Requirements
Build & Test
Measurement
Design Rework Modeling/Simulation withDesign/Process
Capability Flow upStatistical Quality Prediction
“Design in” Quality
Control Critical Design Parameters
Moving From Reactive to Proactive
Design Opportunity Assessment
$
Stage 2 Stage 3 Stage 4 Stage 5Post Launch Performance
DMAIC Efforts Are Focused Here
Maximize LEVERAGE in the Quality Efforts Here!
Cost
to C
orr
ect
Qu
ality
an
d R
eliab
ilit
y
Stage 1
Best Opportunity to Impact Sustaining Quality is in the Design StageBest Opportunity to Impact Sustaining Quality is in the Design Stage
Difficult to see/predictEasy to fix
Easy to seeCostly to fix
Defects are:
Benefits of DFSS
• DFSS Tool Usage
– Defines Customer / Process / Component Specifications (CTQ Identification / Capability Targets Achieved)
– Monitors Critical to Quality Characteristics Throughout the Development Cycle
– Increases Product Development Confidence
– Reduces Product Uncertainty / Risk
– Significant Improvement to Product Quality Levels When Products Are Launched to Manufacturing
– Superior Customer Satisfaction With End Products
Design for Six Sigma as an EnablerDesign for Six Sigma as an Enabler
Typical Process Capability Journey
DevelopmentManufacturing
(Production Environment)
Time
Cpk Target
1.0
0.5
1.0
0.5
Cpk (CTQ’s)
Cpk “Growth” During Development
Cpk “Peaks”Validation Runs
Variation Sets In
Ppk (CTQ’s)
Stage 2 Stage 3 Stage 5 Stage 4 Stage 1
How to Sustain Capability?
• The Integration of DFSS into Product Development Enables Successful Product Strategy to Meet Internal and External Customer Needs
• DFSS Tool Usage Enables Robust Design • DFSS and DMAIC Methodologies Enable
Robust Manufacturing Processes
Cpk Target
1.0
0.5
1.0
0.5
Cpk (CTQ’s) Ppk (CTQ’s)
DFSS Scorecard Process Capability Monitoring
VOC / Concept Evaluation, QFD
Design Reviews DFSS Tool UsageReliability
Reliability M
etrics & Im
provemen
t
SPC, QIP, Lean, 6s Dedicated Resources
Cpk Requirements •Project Contracts•Stage Exit Questions
Resources:•Adv. Mfg. Eng.•Quality Eng.
Stage 2 Stage 3 Stage 5 Stage 4 Stage 1
Ppk on All CTQ’s & Critical Processes
Product Development Manufacturing
Strategic Process Capability Journey
Control Plan
ProceduresImprovement
Activities
Preliminary Analysis
Measurement System
Process Maps
C&EMatrix
FMEA
Measurement System Analysis%R&R, %P/T
Calibration Rqm’ts
Sampling & Testing Plans
SPC Plans
Operating Windows
DOE's
Maintenance Schedules
Training Materials
SOP's
Customer Rqm’ts
Short Term Capability
Long TermCapability
Noise Variable Compensation
ReactionPlans
Trouble ShootingAids
Initial ControlPlan Assessment
Factors Impacting Sustaining Capability
Statistical Process Control (SPC)
SPC Benefits:
– Early Warning of Quality Problems (Proactive Quality Improvement)
– Reduction of Variation (Improve Ppk)
– Trigger for Preventative Maintenance (Improving Service)
Develop Preliminary Business Plan
Identify High Level Customer Requirements
Stage 2Stage 2 Stage 3Stage 3 Stage 4Stage 4 Stage Stage 55 Complete
Design Validation
Complete Manufacturing Process Validation
Prove Manufacturing Readiness for Ramp-up
Complete Reliability Assessment
Complete Product Specifications and Risk Analysis
Complete Design Verification Tests
Accomplish Design for Assembly & Manufacture
Complete Supply Chain Plan
Execute Global Launch Plan
Reconcile Product / Process Performance Against Project Scope
Finalize Customer and Product Requirements
Complete Formal Business Plan
Complete Global Marketing Review
Establish Supply Chain
Complete Proof of Technical Feasibility
Stage Stage 11
Product Development and DFSS Roadmap
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