Design for Six Sigma Workshop

This in-house training covers the principles of design for six sigma following the IDOV (identify, design, optimize and validate) framework. It covers the various principles, tools and methodologies related to each phase of the IDOV framework with examples and exercises to develop an understanding of the DFSS approach.

1. DESIGN FOR SIX SIGMA INTRODUCTION

  • What is Six Sigma
  • Design for Six Sigma Objectives and Role in Product Development
  • Design for Six Sigma Framework – Identify, Design, Optimize and Validate (IDOV)

2. IDENTIFY PHASE

  • Identify Customer Needs – Voice of the Customer (VOC) Process
  • Derive Product Requirements – Quality Function Deployment (QFD)
  • Identify Technical Requirements with Critical to Quality (CTQ) Variables and Specification Limits

3. DESIGN PHASE

  • Develop a Manufacturable Design with Design for Manufacturability/Assembly (DFM/A)
    • Simplify and Standardize
    • Design for Part Handling, Orientation, Ease of Location and Insertion, and Joining/Fastening
    • Design within Process Capabilities
    • Developing and Applying Design Guidelines
  • Identify and Counter Potential Risks Using Failure Modes and Effects Analysis (FMEA)
    • Types of FMEAs
    • Basic FMEA Procedure
    • Taking Corrective Actions
    • Control Plans
    • Managing an FMEA
    • Regulations & Standards
  • Mistake-Proof Design
    • The Six Principles of Mistake-Proofing
    • Identifying Mistake Opportunities and Developing Mistake-Proofing Approaches

4. OPTIMIZE PHASE

  • Assess Process Capabilities To Achieve Critical Design Parameters and Meet CTQ Limits
  • Optimize Design and Reduce Variability – Variation Reduction and Robustness
    • Robust Tolerance Analysis
    • Capability Studies (Cp, Cpk, 6s)
    • Understanding The Results
    • Design of Experiments (DOE)
    • Three Approaches to Robustness
    • Tolerance Analysis – Worst-Case Tolerances, Statistical Tolerances & Process Tolerances

5. VALIDATE PHASE

  • Assess Risks and Plan Test and Validation
  • Identify Key Inputs and Establish Control Plan for Key Inputs
  • Product Validation – Determine Worst Case Conditions and Perform Worst Case Testing
  • Perform Process Validation
  • Verify Capability of Critical to Quality Characteristics