DESIGN for SIX SIGMA

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DFSS, Innovation and I-TRIZ Tools Innovative
Designs for Six Sigma

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BREAKTHROUGH IMPROVEMENT AND INNOVATIVE DESIGN
ORIGINS
Global Leaders in their fields
                  
Dr. Joseph M. Juran Father of Breakthrough
Improvement
Genrich Saulovich AltshullerFather of TRIZ
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OUR CREDIBILITY AND EXPERIENCE

• A 23-year successful Juran track record in
  achieving bottom-line results through pragmatic
  and systematic implementation of quality
  management and breakthrough methodologies for our
  clients.
• The Juran-Ideation partnership creates from the
  strengths and capabilities of two industry
  leaders a synergistic offering of Innovation and
  Six Sigma Performance.
• A proven, comprehensive business approach,
  strategic and tactical due to the depth and
  breadth of the full-time Juran Institute staff
  and services that are unsurpassed by our
  competitors.
• Juran Institute DFSS training and consulting
  materials are experience-based, translated in
  multiple languages. Many of our materials are
  basic references which are used by clients,
  universities and other consultants.
• The DFSS-TRIZ Integration is a unique offering in
  the industry.

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IDEATION INTERNATIONAL INC.

• Ideation established 1992
• Merged with Kishinev School (Leading TRIZ School
  in Russia)
• Headquarters in Southfield, MI
• 85 of the worlds leading TRIZ Scientists
• Installed customer base of over 2,000 enterprises
  worldwide
• Active in 40 countries and 65 universities plus
  numerous partnerships, strategic alliances and
  resellers established worldwide

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IDEATIONS MISSION
Ideation International is a world-class provider
of accelerated education, innovation software
tools, and analytical services based upon the
Ideation/TRIZ Methodology, to enterprises of all
types and sizes. By understanding the mechanisms
that create change, providing the means for
recognizing how to adjust to change, and bringing
the essential benefits of innovation, creativity
and knowledge to enterprises, Ideation will
achieve its mission.
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WHAT IS IDEATIONS BUSINESS?
Provider of I-TRIZ
Education
Software
Publications
Analytical Services
Age of Application
Inventive Problem Solving
Books Papers
54 yrs
Failure Analysis
22 yrs
Anticipatory Failure Determination
Book Papers
Failure Prediction
22 yrs
Directed Evolution
Under Development
Papers
12 yrs
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JURAN INSTITUTES MISSION

• Our mission is to provide
• professional consulting services to
• improve continuously the performance of our
  clients processes, products, people, and profits.

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JURAN INSTITUTE

• Founded 22 years ago by Dr. J. M. Juran.
• Leading source world-wide for research,
  consulting, and education in managing for Six
  Sigma quality to achieve superior business
  results.
• Six Sigma Quality is one of our key businesses
  today. In the present and future, like the past,
  we have built on our competencies - like our
  competitors. One difference, the Juran Quality
  Model is the heart of Six Sigma.
• High quality (high sigma values) reduces costs,
  increases revenues, creates loyal customers and a
  great culture.
• Not all Six Sigma providers are alike. Juran
  Institute tries to adapt and be flexible in
  meeting local site requirements, as well as
  corporate goals.

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WHAT ARE JURAN INSTITUTES SERVICES AND
PRODUCTS?
Provider of Breakthrough
Training
E-learning
Publications
Consulting Services
Licensing
Breakthrough Problem Solving
Books Papers
Design for Six Sigma
Books Papers
Under Development
DMAIC Six Sigma
N/A
Strategic Deployment
Under Development
Papers
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I- DESIGN FOR SIX SIGMADEFINED

• I-DFSS
• The Concurrent Development and Introduction of a
  new or radically redesigned product or service
  and all of the processes (Design, Procurement,
  Production, Logistics and Distribution, Service
  and Sales) that enable the product or service to
  achieve Six Sigma business performance.
• A Phased Methodology which includes both the
  design tools and innovative I-TRIZ tools for
  designing products (goods, information or
  services) and processes that generate customer
  value.
• The phases are Define, Measure, Analyze, Design,
  Verify

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INNOVATIVE DESIGNS FOR SIX
SIGMADEFINED
I-DFSS New Product/Service Introduction to
Achieve Six Sigma Business Performance
MARKET RESEARCH
DESIGN
PRODUCTION
LOGISTICS
DISTRIBUTION
SERVICE
DMADV
SALES
CUSTOMERS
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WHAT IS DESIGN FOR SIX SIGMA (DFSS)?

• Customer-driven design of processes with 6?
  capability.
• Predicting design quality up front.
• Top down requirements flowdown (CTQ flowdown)
  matched by capability flowup.
• Cross-functional integrated design involvement.

• Drives quality measurement and predictability
  improvement in early design phases.
• Utilizes process capabilities to make final
  design decisions.
• Monitors process variances to verify 6? customer
  requirements are met.

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THE DMADVMETHODOLOGY AND TOOLS
DESIGN FOR SIX SIGMA
Under-standcustomerneeds andspecifyCTQs
Developdesignconceptsand high-level design
Developdetaileddesign andcontrol/testplan
Testdesign andimplementfull-scaleprocesses
Initiate, scope,and plan theproject
DELIVERABLES
TOOLS
? Mgmt Leadership ? Customer Research ? FMEA/Error
proofing ? Project ? QFD ? Process
Simulation Management ? Benchmarking ? Design
Scorecards
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SOME OF OUR CLIENTS...
Commercial Electronics South Korea based
company-wide implementation of Six Sigma,
including South Korea, Hungary, India, Indonesia,
Malaysia, Mexico, Spain, United Kingdom and
United States.
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SOME OF OUR CLIENTS...
Satellite Manufacturer Implemented Design for
Six Sigma
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IDEATIONS SUCCESSES-TO-DATEAUTOMOTIVE INDUSTRY

• Dana Corporation
• Rockwell Intl Automotive
• TRW Automotive
• ITT Automotive
• Jaguar

• GM
• Ford
• Toyota
• Chrysler
• Eaton

Cost reduction, warrantees, recalls, new design,
patent circumvention, failure analysis, failure
prediction, training

• Break squeal
• Brake roughness
• Noise and vibration
• Transmission
• Air bag

• Electrostatic paint
• Tail light
• Seat cover
• Wind tunnel
• Plastic fuel tank

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IDEATIONS SUCCESSES-TO-DATECHEMICAL INDUSTRY

• Conoco
• Solutia
• Rohm Haas

• Dow
• Amoco
• Dupont

Cost reduction, breakthrough/discovery,
manufacturing processes, safety, quality,
reliability, failure analysis

• Plastics
• Chemical processing
• Catalysts
• Reactor

• Aromatic oxidation
• Distillation/separation
• New material development/design

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IDEATIONS SUCCESSES-TO-DATEOIL INDUSTRY

• Amoco
• Shell

• Exxon
• Mobil

Cost reduction, reliability, failure analysis,
new design, training

• Exploration
• Method of discovery
• Refineries
• Post processing
• Gas
• Fuel oil
• Enhanced oil recovery

• Dual grading drilling
• Expandable casing
• Hydro carbon processing
• on shore
• off shore
• Transportation

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IDEATIONS SUCCESSES-TO-DATEMEDICAL INDUSTRY

• Johnson Johnson
• Cardiovascular
• Roche

• Bristol Myers
• Zeneca (UK)

New design, patent circumvention, cost reduction,
failure prediction, training

• Medical instrumentation
• Sanitary products
• Blister packaging of pills

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IDEATIONS SUCCESSES-TO-DATEELECTRONICS/ELECTRIC
AL INDUSTRY

• Honeywell
• Motorola
• Philips Electronics
• Hitachi
• ITT
• Arteche (Spain)
• Visteon

• Northern Telecon (Canada)
• Solarex
• Helix
• Toshiba
• Sony
• LG Electronics

Cost reduction, new technologies, reliability,
manufacturing processes, training

• Cell phones
• Microchips
• PC boards
• Radio

• Headset
• High voltage transformers
• Power supplies
• Navigation systems

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IDEATIONS SUCCESSES-TO-DATEAVIATION INDUSTRY

• Boeing
• Pratt Whitney
• Techspace Aero (Belgium)
• Honeywell
• Allied Signal
• Rockwell International

• Rolls Royce
• McDonnel Douglas Aerospace
• NASA
• Hughes Aircraft
• TRW
• BF Goodrich
• Litton

Cost reduction, safety, reliability, quality, new
design, failure analysis and prediction, training

• C-17
• F-22
• Engines

• Valves
• Containment ring

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I-DFSS DESIGN PROJECT
CASE 1
CASE 2
CASE 3
No Current Product or Process
CurrentProduct
? DPMO COPQ
? DPMO COPQ
CurrentProduct
NewProduct
But
CTQs
Current Processes
High-level Design
Design
Design
CTQ GAPBase LinePerformance
Manufacturing
? Cp, Cpk COPQ
Distribution
DesignScorecard
Service
Marketing
REDESIGN
NEW PROCESS DESIGN
NEW PRODUCT AND PROCESS DESIGN
Base Line Performance OK
Product Base Line Performance OK(May be of
little value)
No Base Line Performance
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SCIENTIFICALLY BASED APPLICATIONS SYSTEMATIC,
STRUCTURED INNOVATION
Strategically Evolving Future Generations of
Technologies Systems
Directed Evolution
DE
Inventive Problem Solving
Anticipatory Failure Determination
AFD
IPS
Surgical Removal of Tough Technological Problems
Failure Analysis
Failure Prediction
Elimination of Contradictions
Invention of Failure Modes
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I- DESIGN FOR SIX SIGMA

• Pre-DEFINE Phase
• INTRODUCTION TO SIX SIGMA
• HOW TO THINK ABOUT DFSS/NEW PRODUCT INTRODUCTION
  (NPI)
• I-TRIZ/Directed Evolution (DE)
• Strategic vision
• Logical chain of product concepts
• Product evolution roadmap

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I- DESIGN FOR SIX SIGMA

• DEFINE Phase
• INTRODUCTION TO DEFINE
• ESTABLISH DESIGN PROJECT
• FINANCIAL ANALYSIS
• PROJECT MANAGEMENT AND RISK ASSESSMENT
• SUMMARY ISSUES TO CONSIDER

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I- DESIGN FOR SIX SIGMA

• MEASURE Phase
• INTRODUCTION TO MEASURE
• ESTABLISH CTQs AND CTIs
• I-TRIZ/Innovation Situation Questionnaire
  Problem Formulator
• Design problem documentation
• Design expectations
• INTRODUCTION TO PROBABILITY, STATISTICS AND
  PREDICTION
• MSA (Variables, Attribute and Data quality)
• PROCESS CAPABILITY (Variables and Attribute)
• RISK ASSESSMENT
• I-TRIZ/Anticipatory Failure Determination (AFD)
• Failure prediction
• DESIGN SCORECARD

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I- DESIGN FOR SIX SIGMA

• ANALYZE/HIGH-LEVEL DESIGN Phase
• INTRODUCTION TO HIGH-LEVEL DESIGN
• DEVELOP DESIGN ALTERNATIVES
• I-TRIZ/Innovative Problem Solving (IPS)
• Description of design options (alternatives)
• Analysis of design alternatives for technological
  barriers and contradictions
• DEVELOP HIGH-LEVEL DESIGN (VA/VE)
• MULTI-VARI ANALYSIS
• CONFIDENCE INTERVALS AND SAMPLING
• HYPOTHESIS TESTING AND ANOVA
• EVALUATE HIGH-LEVEL DESIGN
• I-TRIZ/Anticipatory Failure Determination (AFD)
• Failure analysis and prediction

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I- DESIGN FOR SIX SIGMA

• DETAIL DESIGN Phase
• INTRODUCTION TO DESIGN
• RISK ASSESSMENT/FALURE ANALYSIS
• I-TRIZ/Anticipatory Failure Determination (AFD)
• Failure analysis
• TAGUCHI METHODS AND ROBUST DESIGN
• TOLERANCING
• DOE with RSM

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I- DESIGN FOR SIX SIGMA

• DETAIL DESIGN Phase (contd)
• RELIABILITY and AVAILABILITY
• NON-PARAMETRIC STATISTICS
• SIMULATION with Monte Carlo Methods
• DESIGN FOR MANUFACTURABILITY/DESIGN FOR ASSEMBLY
• DVT/TESTABILITY
• DESIGN SCORECARD

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I- DESIGN FOR SIX SIGMA

• DETAIL DESIGN Phase -- CUSTOM FEATURES
• THE TOOLS OF DETAIL DESIGN
• CONCURRENT ENGINEERING
• SOFTWARE ENGINEERING METHODS AND TOOLS
• (CMM, CASE)

• ENHANCED DESIGN FOR
• Commercial/Competitive Success
• Manufacturability
• Serviceability
• Reliability
• Availability
• Information Management
• Control

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I- DESIGN FOR SIX SIGMA

• VERIFY Phase
• INTRODUCTION TO VERIFY
• DESIGN FOR CONTROL
• DESIGN FOR MISTAKE- AND FOOLPROOFING
• STATISTICAL PROCESS CONTROL (SPC)
• MVT
• TRANSITION TO PROCESS OWNERS
• I-TRIZ/Directed Evolution (DE)
• Logical sequence of new scenarios
• Strategic knowledge base and patent portfolio
• Targeted competitive intelligence
• New product evolutionary stages
• SUMMARY ISSUES TO CONSIDER PROJECT CLOSURE

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I- DESIGN FOR SIX SIGMA

• VERIFY Phase -- CUSTOM FEATURES
• PILOT TESTING
• FULL-SIZE SCALE-UP AND COMMERCIALIZATION
• DESIGN INFORMATION AND DATA MANAGEMENT
• LEAN MANUFACTURING

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I- DESIGN FOR SIX SIGMA
? DMADV Training/Project Map
IDEAL
15 - 16 Weeks
Training Weeks Project
D-M
A
D
V
1 3 1
4 1 4 - 6 1
4 - 6
V
DR-3
D
DR-2
A
PP
D-M
DR-4
DVT
MVT
19 - 22 Weeks (5-6 Months)

• Critical Success Factors
• Project starts with training
• Project lt 6 months
• Project phases match training schedule

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I- DESIGN FOR SIX SIGMA
? DMADV Training/Project Map
REAL
(A)
?
Training
Project
Mass Production
Start
DR-2
OK
(B)
D-M
Training
Start
Consulting
(C)
?
Training
DR-3
Start
No
(D)
Training
Project
Gap
Start
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SIX SIGMA DMADV TRAINING FLOW
JURANSr. Instructor
Executive Briefing
4-8 hrs
Preparations
JURAN Sr. Instructor
Champion Training/Workshop
2 days
Go-No go Decision

• DMADV

Black Belt Training
Black Belt Project
JURANINSTRUCTOR(first wave)
Total Duration 4-6 months
Trained Black Belt
CertifiedBlack Belt
No
?
Yes
Master Black Belt Program
JURANSr. INSTRUCTOR
Total Duration 4-6 months
Master BlackBelt Project
Certified MBBs