1. © 2003 Six Sigma Academy0 3 Day DFSS Workshop April 1-3, 2003 What Is DFSS

2. © 2003 Six Sigma Academy1 What is Design for Six Sigma? DFSS is a system of Six Sigma principles and methods (statistical and non-statistical) that allows a design team to deliver products, processes, or services to 1.Define robust configurations that incorporate mature activities, parts, components and processes that have already been optimized, or at the minimum characterized 2.Minimize absolute complexity and its relative influence on system performance 3.Design or reconfigure necessary processes in such a way that they produce products or services whose customer defined key features are produced at a six sigma level Design with the Power of Six Sigma 

3. © 2003 Six Sigma Academy2 1. Define Robust Configurations A product or service is created as a result of multiple steps or processes The capability of these processes can be measured (MSA/Process Capability) and a Z value assigned If the process is capable (it can support six sigma output of the CTSs), it can be incorporated into the design If the process is not capable, a DMAIC project can be assigned to improve its capability or the designer will have to find an alternate process or design DFSS Relies on DMAIC Skills for Process Measurements and Improvements

4. © 2003 Six Sigma Academy3 2. Minimize Absolute Complexity If a process has 50 steps ( or a product has 50 parts) with a capability of 99.9% good at any one step (1 /1000 defective per operation), we end up with 5% total defects If a process has 50 steps with a capability of 99% good at any one step (1 /100 defective per operation), we end up with 39.5% total defects DFSS applies the solution of simplification/step reduction to eliminate or reduce the effect of rolled throughput yield issues (especially when forced to use marginally acceptable processes) Complexity Is Not Better

5. © 2003 Six Sigma Academy4 3. Meet the Customer’s Needs A product or a process has many features, dimensions, and attributes. A car likely has over a hundred-thousand – think of every part, every fastener and think of dimensions, colors, surface finish, strength, etc. think also of the safety and performance features So a DFSS designer must first understand what features are truly critical to the customer’s satisfaction (CTS) and then: Understand what functional requirements must be met to provide the customer with the features and quality critical to their satisfaction (CTS) and then: Create a design that is capable of producing these functional requirements to a six sigma level of quality and that is robust to the noise of the process CTS Functional requirements Design Parameters

6. © 2003 Six Sigma Academy5 What Is DFSS? Common Gated Design Process Six Sigma Key Design Principles Innovativ e Design (D) Robust Design (V) Voice of Customer (I) Transfer Function (O) Score Card Rally Points A Powerful Competitive Edge

7. © 2003 Six Sigma Academy6 Outcomes of DFSS Common Gated Design Process Six Sigma Key Design Principles Innovativ e Design (D) Robust Design (V) Voice of Custome r (I) Transfer Function (O) Score Card Rally Points A Powerful Competitive Edge = Market Predictable Design Manufacturable Product Satisfied Customers Common Design Language Enhanced Design Leadership Team (Develop, Codify, Sustain)