1. Phong Q. Vo Dec 2, 2011 Design For Six Sigma & Structured Innovation

2. 2 Credentials l B.A.Sci. in Mechanical Engineering, UW, 1989 l M. Eng.in Mechanical Engineering, UWO, 2003 l M.B.A., WLU, 2006 l Certified DFSS BB since 2007 l A member of PEO since 1993 l GM/GDLS employee since 1990, held various positions in engineering department (Design, Computer Modeling & Simulation, Engineering Quality, Systems Engineering) l A good friend of Dr. P. Kurowski

3. 3 Topics of Discussion ä Definition of Quality ä What is 6 sigma? ä 6 sigma benchmark ä Lean six sigma (LSS), Design For Six Sigma (DFSS), Differences ä Phases in a DFSS project ä Structured Innovation & TRIZ ä Questions

4. 4 Definition of Quality l “A characteristic or attribute of something; property; a feature” – The Houghton Mifflin Canadian Dictionary l “Characteristic of a product or service that satisfies the customer's wants and needs in exchange for monetary considerations” - Web definition l “High quality product or service can only be achieved by well/systematically designed process, disciplined execution, and the right attitude of the people involved” – P.Q.V.

5. 5 What is Six Sigma ? l A disciplined, statistically driven methodology for eliminating or reducing defects (or waste) in any process. l Originally developed by engineers at Motorola in the 1980’s to improve the company’s quality monitoring process. l To day, the six sigma principles are used worldwide as a management tool to improve business outcomes.

6. 6 An illustration Process to meet control limits Control Limits established to meet customer expectations Sdfsdfsd sdffsdf Sdfsdfsd Sdffsdf Czxczxc czx

7. 7 6 Sigma Process Benchmark Sigma LevelDPMAssessment 1 sigma697,672Non-competitive 2 sigma308,770Non-competitive 3 sigma66,811Non-competitive 4 sigma6,210Industry Average 5 sigma233Industry Average 6 sigma3.4World Class

8. 8 What is Lean Six Sigma (LSS)? l The application of lean six sigma philosophy to produce better products, at faster rates, and at lower costs. ä Lean means eliminating non-value added steps in a process. ä Six Sigma means reducing variation of a lean process. In other words, the process produces no more than 3.4 defects per million. ä Synonymous with DMAIC (Define, Measure, Analyze, Improve, Control)

9. 9 What is Design For Six Sigma (DFFS)? l A proactive, predictive, and systematic design approach to develop six sigma quality level products or services. l Synonymous with DCOV (Define, Characterize, Optimize, Validate)

10. 10 Main Differences between DFSS and LSS ? LSSDFSS ReactiveProactive identifies problems and modifies existing processes concentrates on up-front designs and processes Benefits are easy to quantify Benefits are long-term.

11. 11 Phases in a DFSS project Define Characterize Optimize Validate

12. 12 Define Phase l Voice of Customers (VOC) ä House of Quality #1 House of Quality #1 ä CTC (Critical to Customers) ä Balance Scorecard (Parts, Process, Performance, Software) Balance Scorecard Define

13. 13 Characterize Phase l Systems Engineering & Requirements Flow-down l House of Quality #2 l Creation of Transfer Function (DOE, EVA) l Design Concept Development l Design Risk Assessment l Design Concept Selection Characterize

14. 14 Optimize l Design for Robust Performance l Tolerance Allocation l Design for X (Manufacturability, Reliability, Maintainability, Assembly, etc.) l Product Capability Prediction Optimize

15. 15 Validate l Prototype construction l Predicted vs. Actual comparison l Sensitivity Analysis Validate

16. 16 Structured Innovation - TRIZ l TRIZ stands for “ Teoriya Resheniya Izobreatatelskikh Zadatch” (A Russion acronym). It means “Theory of Inventive Problem Solving” l Genrich Altshuller, the father of TRIZ ä Born in Oct. 1926, in Tashkent, USSR ä Died on Sept. 24 th, 1998 in Petrozavodsk, Russia. ä An engineer, inventor, scientist, journalist, and writer. ä The story of G. Altshuller at Gulag concentration camp

17. 17 More on Altshuller & TRIZ

18. 18 More on Altshuller & TRIZ l Altshuller screened over 200,000 patents and looked for patterns in problem solving techniques l Altshuller concluded that ä There are a finite number of potential problems and solutions in the universe ä Innovation is a solution resolving major design conflicts (physical & technical contradictions) ä All problems can be framed within 39 parameters ä They can be solved using 40 principles

19. 19 Traditional Problem Solving Process Problem A Ideal Solution Traditional Problem Solving Process The Wall

20. 20 TRIZ Process Problem A Ideal Solution TRIZ Process starts here

21. 21 TRIZ Process Specific Problem Generic Problem Generic Solution Specific Solutions

22. 22 Questions