Design for Six Sigma: A Roadmap for Product Development Second Edition

Contents......Page 9
Preface......Page 15
Preface to the First Edition......Page 17
1.1 What Is Quality?......Page 23
1.2 Quality Assurance and Product/Service Life Cycle......Page 25
1.3 Development of Quality Methods......Page 30
1.4 Business Excellence, Whole Quality, and Other Metrics in Business Operations......Page 39
1.5 Summary......Page 42
2.1 What Is Six Sigma?......Page 43
2.2 Process: The Basic Unit for the Six Sigma Improvement Project......Page 44
2.3 Process Capability and Six Sigma......Page 50
2.4 Overview of Six Sigma Process Improvement......Page 56
2.5 Lean Operation Principles......Page 61
2.6 Process Mapping, Value Stream Mapping, and Process Management......Page 67
2.7 Six Sigma Goes Upstream: Design for Six Sigma (DFSS)......Page 76
2.8 Summary......Page 77
3.1 Introduction......Page 79
3.2 More on the Product Development Process......Page 81
3.3 Lean Principles in Product Development......Page 93
3.4 Lean Product Development Approaches......Page 96
3.5 What Is Design for Six Sigma?......Page 108
3.6 Why “Design for Six Sigma”?......Page 111
3.7 Design for Six Sigma (DFSS) Phases......Page 113
3.8 More on Design Process and Design Vulnerabilities......Page 117
3.9 Differences between Six Sigma and DFSS......Page 119
3.10 What Kinds of Problems Can Be Solved by DFSS?......Page 121
3.12 Features of a Sound DFSS Strategy......Page 123
Appendix: Historical Development in Design......Page 125
4.2 Black Belt–DFSS Team: Cultural Change......Page 129
4.3 DFSS Deployment Prerequisites......Page 132
4.4 DFSS Deployment Strategy......Page 134
4.5 DFSS Deployment Strategy Goals......Page 137
4.6 Six Sigma Project Financial Management......Page 144
4.8 Elements Critical to Sustain DFSS Deployment......Page 145
4.9 DFSS Sustainability Factors......Page 146
5.1 Introduction......Page 151
5.2 Form a Synergistic Design Team (DFSS Algorithm Step 1)......Page 154
5.3 Determine Customer Expectations (DFSS Algorithm Step 2)......Page 155
5.4 Understand Functional Requirements Evolution (DFSS Algorithm Step 3)......Page 169
5.5 Generate Concepts (DFSS Algorithm Step 4)......Page 170
5.6 Select the Best Concept (DFSS Algorithm Step 5)......Page 174
5.7 Finalize the Physical Structure of the Selected Concept (DFSS Algorithm Step 6)......Page 175
5.8 Initiate Design Scorecards and Transfer Function Development (DFSS Algorithm Step 7)......Page 179
5.9 Assess Risk Using DFMEA/PFMEA (DFSS Algorithm Step 8)......Page 181
5.10 Transfer Function Optimization (DFSS Algorithm Step 9)......Page 189
5.11 Design for X (DFSS Algorithm Step 10)......Page 196
5.12 Tolerance Design and Tolerancing (DFSS Algorithm Step 11)......Page 198
5.13 Pilot and Prototyping Design (DFSS Algorithm Step 12)......Page 200
5.14 Validate Deign (DFSS Algorithm Step 13)......Page 201
5.15 Launch Mass Production (DFSS Algorithm Step 14)......Page 202
5.16 Project Risk Management......Page 203
5.17 Other DFSS Roadmaps......Page 204
6.1 Introduction......Page 207
6.3 DFSS Design Synthesis......Page 208
6.4 Design Scorecards and Transfer Function Development......Page 217
7.1 Introduction......Page 235
7.3 QFD Benefits, Assumptions, and Realities......Page 237
7.4 QFD Methodology Overview......Page 238
7.5 Kano Model of Quality......Page 246
7.6 The Four Phases of QFD......Page 247
7.8 QFD Example......Page 248
7.9 Summary......Page 258
8.1 Introduction......Page 259
8.2 Why Axiomatic Design Is Needed......Page 260
8.3 Design Axioms......Page 261
8.4 The Independence Axiom (Axiom 1)......Page 262
8.5 Coupling Measures......Page 274
8.6 The Implications of Axiom 2......Page 284
8.7 Case Study: Axiomatic Design of the Water Faucet......Page 291
8.8 Summary......Page 294
Appendix 8A: Axiomatic Design Theorems and Corollaries......Page 295
Appendix 8B: Historical Development of Axiomatic Design......Page 300
9.1 Introduction......Page 303
9.2 TRIZ Foundations......Page 307
9.3 TRIZ Problem-Solving Process......Page 317
9.4 Physical Contradiction Resolution/Separation Principles......Page 320
9.5 Technical Contradiction Elimination—Inventive Principles......Page 329
9.6 Functional Improvement Methods/TRIZ Standard Solutions......Page 336
9.7 Complexity Reduction/Trimming......Page 352
9.8 S-Curve Analysis of Technical Systems......Page 353
9.9 Evolution of Technological Systems......Page 355
9.11 Comparison of Axiomatic Design and TRIZ......Page 361
Appendix: Contradiction Table of Inventive Principles......Page 369
10.1 Introduction......Page 375
10.2 Design for Manufacture and Assembly (DFMA)......Page 378
10.3 Design for Reliability (DFR)......Page 387
10.4 Design for Maintainability......Page 389
10.5 Design for Serviceability......Page 390
10.6 Design for Environmentality......Page 400
10.7 Design for Life-Cycle Cost (LCC): Activity-Based Costing with Uncertainty......Page 402
10.8 Summary......Page 407
11.1 Introduction......Page 409
11.2 FMEA Fundamentals......Page 412
11.3 Design FMEA (DFMEA)......Page 418
11.4 Process FMEA (PFMEA)......Page 428
11.5 Quality Systems and Control Plans......Page 432
12.1 Introduction to Design of Experiments (DOE)......Page 435
12.2 Factorial Experiment......Page 440
12.3 Two-Level Full Factorial Designs......Page 448
12.4 Fractional Two-Level Factorial Design......Page 459
12.5 Three-Level Full Factorial Design......Page 468
12.6 Incomplete Factorial Experiments......Page 472
12.7 Summary......Page 490
13.1 Taguchi's Orthogonal Arrays......Page 491
13.2 Taguchi Experimental Design......Page 494
13.3 Special Techniques......Page 498
13.4 Taguchi Experiment Data Analysis......Page 505
Appendix: Selected Orthogonal Arrays......Page 513
14.1 Introduction......Page 521
14.2 Loss Function and Parameter Design......Page 522
14.3 Loss Function and Signal-to-Noise Ratio......Page 530
14.4 Noise Factors and Inner-Outer Arrays......Page 538
14.5 Parameter Design for Smaller-the-Better Characteristics......Page 543
14.6 Parameter Design for Nominal-the-Best Characteristics......Page 547
14.7 Parameter Design for Larger-the-Better Characteristics......Page 550
15.1 Introduction......Page 555
15.2 Design Synthesis and Technical Systems......Page 557
15.3 Parameter Design for Dynamic Characteristics......Page 568
15.4 Functional Quality and Dynamic S/N Ratio......Page 587
15.5 Robust Technology Development......Page 590
16.1 Introduction......Page 593
16.2 Worst-Case Tolerance......Page 598
16.3 Statistical Tolerance......Page 602
16.4 Cost-Based Optimal Tolerance......Page 609
16.5 Taguchi's Loss Function and Safety Tolerance Design......Page 614
16.6 Taguchi's Tolerance Design Experiment......Page 621
16.7 Computer-Aided Robust Parameter and Tolerance Design......Page 624
17.1 Introduction......Page 633
17.2 Search and Identify the Region That Contains the Optimal Solution......Page 637
17.3 Response Surface Experimental Designs......Page 644
17.4 Response Surface Experimental Data Analysis for Single Response......Page 650
17.5 Response Surface Experimental Data Analysis for Multiple Responses......Page 654
17.6 Mixture Experiments......Page 664
18.1 Introduction......Page 687
18.2 Design Analysis and Testing......Page 692
18.3 Prototypes......Page 704
18.4 Process and Production Validation......Page 711
18.5 DFSS Validation and Measurement......Page 719
Appendix: Glossary of Terms......Page 724
Acronyms......Page 727
References......Page 731
A......Page 739
C......Page 740
D......Page 742
F......Page 746
I......Page 748
L......Page 749
M......Page 750
N......Page 751
O......Page 752
P......Page 753
Q......Page 755
R......Page 756
S......Page 757
T......Page 759
V......Page 762
Z......Page 763