R & D ??? ???? 6??? ?? ?? ? ??

1
R D ??? ???? 6??? ?? ?? ? ?? (Design For Six
Sigma)
Six Sigma Changing the Game With Quality
2000. 8. 18
? ? ? DFSS TF?
2
6 ?????
??? ??? ??? ??? ??? ??? ????? ??? ???? ??? ????
?? ???? ??? ???? ????? ????? ???? ??????.
?? ?? ?? ???
(????)
(??)
????
???? ??
Six Sigma
Six Sigma
?? Tools
??
R D
??? ??
3
6??? ????
3s
4s
4.7s
4.8s
5s
5.1s
6s
1??
2??
3??...
DFSS ????
? ??? ??? ?? ??
? ???? ?? ??
? ?? ?? ??
??
s ????
????) Six Sigma MIKEL HARRY RICHARD SCHROEDER
2000. 2
4
????? 6???
Sigma Level
Cost Of Quality
Defects Per Million Opportunities
Not applicable
2 Sigma
308,537(Noncompetitive companies)
66,807
3 Sigma
???? 2540
6,210 (Industry average)
4 Sigma
???? 1525
???? 515
233
5 Sigma
???? 1 ??
3.4 (World class)
6 Sigma
? ? ??? ??? ? ?? ??? 10? ???? ??? ????.
????) Six Sigma MIKEL HARRY RICHARD SCHROEDER
2000. 2
5
???????
??? ????? ???? ??
5
25
??? ??? 5
70
? ????? ??? ??? ?????.
5s ???? ?????? 20 ??? ?? ??
3s ??? ??? ???? 25? ????
6
??? ???? ??? 6??? ??? ??
??????
6??? ??
???? ??
a
Six Sigma
?? Tools
??? ??
? Black Belt? ?? ?? ??? (CTQ ?? -gt ???? ??)
? ???? ????
? ??? BB? ???? ??? ???? ?? ??.
7
Process Tollgate
??
Design
Identify
??
What are the possible solutions? What is the best
potential solution? What are the key inputs? What
are the functional relationships? Do you have
data to support your answers? How confident are
you?
What is most important? What are the biggest
gaps? What is the risk? What constraints
exist? Who are the key players? What is your plan?
??
??
6??? ????? ??? ??? ???? ?? ??? ???? ?? ??? ??
???? ??????.
??
Optimize
Validate
??
How sensitive to input variability? How sensitive
to environmental variability? How meaningful are
the specifications? What is the long term
capability?
??
Can you demonstrate a capable process? How stable
is your process? What are the key factors to
control? What control mechanisms are in
place? What is the action plan when out of
control?
??
? ?? ???? ???? ??? ?? ???? (???? ????)
8
? The DFSS Road Map
????
DFSS
Mfg.
R D I D O V C S I
R D M A I C S I
Known
Unknown
DFSS Methodology
? ?
Good Results
Integrate
? (Common Sense)
Standardization
Right
A C T I O n
Control
Bad Results (Negligence)
Bad Results (Incompetence)
M-A-I-C I-D-O-V
Wrong
N/A (Challenge Area)
Define Recognize
Nothing (Ignorance)
None Action
SIMPLIFY
INTEGRTY
STANDARDIZATION
9
DFSS? ???
? ?? ??? DFSS? ??? ????
10
??? 3? ??
? ??) ???? ???? ??? ???.
(Prevention Cost) ? ?) ?? ???? ???
???? ???? ??? ???. (Appraisal Cost) ? ?)
?? ???? ???? ?????? ??? ????. (Failure Cost,
IF/EF)
10001 PRODUCT DEFINITION
1001 PRODUCT DESIGN
101 PROCESS DESIGN
11 PRODUCTION
PRODUCT IMPROVEMENT
11
Why DFSS ? (Example)

590,000
?) ?? Ricoh?? ????
368
177
37
????
??????
?? ???
????
12
Promotes a fuller understanding...
Who Casts the Biggest Shadow?
Adapted from Ford Motor Co.
13
5 ???? ?? ???.
s ??
6 s
????? ??? ??? ??
DFSS??
5s ??
5 s
4 s
????? ???, ??????
3 s
6 ?????
14
DMAIC vs. DFSS Project
??
??
USL
LSL
T
15
DFSS? ??? ?? ?? (??? ?? ?? ????)
Right Project Right People Right Process
16
DFSS Strategy
6 ???
?? (Body)
?? (Engine)
Is it Real? Can we Win? Is it Worth?
?? (Wheel)
Right Project
Right People
Right Process
Methodology
Procedure
strategy
(??)
(??)
(??)
? ??/??/????(DFSS) (D - I - D - O - V )
? ??????
? ????????
? ??/???? (SQM) ( D-M - A - I - C )
? Project????
? ??/???? (TRJT) ( D-M - A - D - V )
? Personal????
Right Roadmap
17
DFSS? ?? ??? ?? Right Project ?? ?? 6Ys?
GOs ?? ?? ????
18
Critical Function? ??? ??? ?? ??? ??? ??
Physical Law Underwrites Ideal Functions
??? ??? ??
???? ??? ??? Scalars ? vectors? ???? ??.
??? ???? ... ??? ??? ???!
Computer-Aided Data Acquisition ?? ???? ?? ??
??? ?? ?? ???? ?? ??
19
Critical Parameter Management
? CGI (Capability Growth Index)? 6???
??(Zvalue)? ?? ???? ??
? CIP (Cost Improve Parameter) ?? ?? ????
System Level
A Few Critical Measures
CTQ (Critical To Quality)
More Critical Measures
Subsystem Level
???? ??? ??? Scalars ? vectors? ???? ??.
CFR (Critical Functional Response)
Many Critical Measures
Component Level
CAP (Critical Adjustment Parameter)
Many, Many Critical Measures
Mfg. Process Parameter Level
CTF (Critical To Function)
20
Understanding CFR/CAP/CTF
21
DFSS Project Select Guide
1. ????? ?? ??? ???? ?
? ???? ?? ? ??? ?? ? ??? ??
If ??,??? ??(????)
MAIC/MADV
CTQ
? ? ??? ?? ????? ???? ????? ??? ?? ??? ?????
Yes(Scalar, Vector )
(Energy ??? ??)
Mfg/Admin
2. ??? ?? ??? ???? ?
? ? ? ? ? ?
????? ?? ???(??,?? ??)
No
???
? ????(???? ??) ? ??? ??? ?? ?? ? ???? ????
?? ? ??? ??/??? ??
Yes
3. ????? ?? ??? ??? ???? ?
EPI Process
???
?? PJT ?? PJT
? CPM(Critical Parameter Management)
PJT ??
? CGI (Capability Growth Index)
BB
4. ????? ?? ??? ??? ???? ?
(CFR/CAP/CTF)
? ??? ?? ? ??? ?? ?? ? ??? ??
No
??? ???
Yes
5. ????? ?? ??? ???? ???? ?
?????
Cp,Cpk
6. ????? ?? ??? ?? ??? ???? ?
Y f (SXn) f (SX noize)
? S/N Ratio ? CIP(Cost Improve Parameter)
7. ????(????)? ?? ????? ???? ?
? ???? ??? ?? Tool ??
4?? ??
1? ??
GB ????
6??
4??8??
8. ????? ?? CFT? ?? ???? ?
No
? CFT ??? ????? ????? ? ??? ?? ???? ??? ?????
CFT
Yes
9. ????? ?? ??? ???? ?
? ????,??????,???? ? ??????(??????,???????)
No
??lt2?
Yes
FEA? ??? ?????
???? ?? ?? ? ??
DFSS? ???? ???
22
DFSS? ?? ??? ?? DFSS BB?? ?? ??
23
DFSS BB Training Course
24
DFSS Process
EPI
??????
????
????
????
(Identify CTQ)
(Validate)
(Design)
(Optimization)
??? ??? ?????
??? ??? ???
?? ??? ?? ?? ? ????
??? ?????
QFD 2 step DFMEA CAE DFA/DFM
KJ Mapping QFD 1 step
??,?? ??
CTQ Z Value ??
Pilot Data
Multi-Var. PFMEA
??Pilot Data
CGI3
Identify CTQ
Technical Requirements
??? Needs (VOC)
????
CGI2
CGI1
?? ??
CPM??
M-A-I-C (Mfg 6s)
Z Value ????
???? (75)
??spec Simulation ????
???? Data?? (Cp.Cpk)
CTQ Z Value ??
????
????
CGI4
Define
Identify CTQ
Design
Optimize
Validate
DFSS
Concept Design - CPM ?? - ?? CFR ?? (???) -
CFR? ???/?? ?? - BB PJT? ???
Parameter Design - Gap Zero? ?? Parameter
Design (????/?? ??) - Vital Few (CAP)??
??? CTQ ?? - GOs 6Ys?? - Bench Marking - ??
Tree ?? - Champion PJT ??
Tolerance Design - Robustness - S/N ??? -
????? ??? - Zst 6.0 ??
Reliability Design - ??? ?? - ??? ?? -
CGI/Checklist/DSC - Zlt 4.5 ??
CPM
-Process Mapping -CE Matrix -Control Plan for
Design -DFMEA -MSA -Capability Study -Basic
Statistics Intro to Minitab Basic Stats
Graphics Central Limit Theorem Hypothesis
testing Confidence Interval -Project
Definition /Chartering
-TRIZ(1/2 or 1 day) -DFMA -Modular
Design -t-Test -ANOVA -Balanced ANOVA -DOE -DOE
Planning -2k method -Fractional
Factorial -Regression -Statistical
Tolerance -Crystal Ball -Tolerance
Modeling -Drawing -GDT
-Reliability -Validation Testing -Multi-Vari
-Design Capability Assessment -SPC -Control
Plan for MFG.
-RSM -Static/Dynamic S/N -Optimization -Robust
Design -Taguchi Method -Matrics -Quality Loss
Function -Empirical Tolerancing
-DFSS Overview -Phase Gate -Understanding
Values -Customer Involvement -Business
Planning -Managing Customer Value -Market
Segmentation -Concept Engineering -Plan for
Customer Visit -Customer Interview -Image
KJ -Customer Requirement KJ -QFD -Idea
Generation -Pugh Concept Selection -CPM
Tools
25
DFSS? ?? ??? ?? Right Process ????? ??
26
DFSS Process Roadmap
DFSS? ?? ????? ? ???
Product
EPI Process
Page 6 ??(5. DFSS Methodology)
Right Design
????
????
????
??????
???? ??? ????
Robust Design
VOC
DFX
(TRIZ,GDT,TD)
(DOE,FMEA,RR)
(BSC,QFD)
(PFMEA)
CIS
Change No.
ECM (Engineering Change
Management)
DSC (Design Score Card)
SAP R/3
Change History
ACS
??? ? ???
Document Structure
Material Master
EBOM
MBOM
PDM (Product Data Management)
??? ?? ?? ??? ??
WBS
VAULT
BSC (Balanced Score Card)
?? (CTQ)
DFSS ????
???? (cpk)
? ?? ? ??
DFSS
??/??
Money
????
(KBM) Knowledge
Page 4 ??(3. DFSS Stretch Goal)
27
6 ??? ???

• P D C A Model
• M A I C Model
• P C O R Model
• S M A R T Model
• C S I Model
• M A D V Model
• I D O V DFSS Model
• D D O V DFSS Model
• C P T P DFSS Model
• R C I DFSS Model

28
??SDIs DFSS Roadmap
Invent Innovate
Develop
Optimize
Certify
C D O C (????) - ??
Capability
Concept
Optimize
Design
I D O V (????) - ????
Design
Optimize
Verify
Identify
29
??? Design Review? ?? ?? Check-list Score-card
30
DSC (Design Score Card)
EPI Process
????
????
????
??????
?? ??? ?? ?? ? ????
??? ??? ?????
??? ??? ???
??? ?????
DFX
Robust Design
VOC
(PFMEA)
(???,GDT,TD,TRIZ)
(DOE,FMEA,RR)
(BSC,QFD)
DR1 (DSC)
DR2 (DSC)
DR3 (DSC)
DR4 (DSC)
??
???
??
??
??
???
??
??
? ?
? ?
? ?
? ?
??
Score
??
Score
??
Score
??
Score
80? ??
80? ??
80? ??
80? ??
BSC
???
DOE
95
95
83
92
Simulation
80? ??
80? ??
80? ??
80? ??
VOC
GDT
RR
PFMEA
88
88
81
89
Tolerance Design
80? ??
80? ??
80? ??
80? ??
91
91
87
64
QFD
DFMEA
DFX
80? ??
80? ??
80? ??
80? ??
??
TRIZ
Robust
??
64
84
86
94
80? ??
80? ??
80? ??
80? ??
DFSS Score
84.5
DFSS Score
89.5
DFSS Score
DFSS Score
90.5
78.5
? ?? ????,????? ?? ??
? ?? ? DR? ????? BSC(??,??,?? ????,??? ??) ???
?? -gt ? ?? ?
31
DFSS? ?? ??? ??? ??? ??? ???? Audit ??
32
DFSS Technology Standard Structure
??
?? ???
?? ??
??/Spec ???
??
???? ??? ?? ???? ????
??
?? ???
?? ??
??
????
???(Cell)
????(SQM)
DFSS ????
????
????
????
????
????
?????
??
? ????? ? GDT ? Gage RR ? Tolerance Design
- Vector Loop - RSS - Monte Carlo
Simulation ? CAD/CAM/CAE
? VOC ? QFD ? BMT
? DOE ? Gage RR ? TRIZ
? DFX ? FMEA
33
Definition of standard
????
????? ?? ??? ??? ??? ??? ?? ?.
?? Process ?? ??
NO
?? ??/??? (???)
??
??? ???
Yes
??? ??? ??? ?????? ??? ??? ??? ??? ??? ??? ???
???? ???
?? ??
NO
??
?? ??? (???)
Yes
NO
???
?? ??? (????)
Yes
??? ?? ?? ??? ?
?? ??? ??
34
DFSS Process? ??? PDM ???
35
Data Flow in SAP R/3
SAP
CAD
External DB of Parts (CIS, ACS)
CAD Libraries
CAD I/F
Material Master

• Mechanical
• Electronic

ROH
FERT
EMDL
ECM
EASM
HALB
Apply to Objects
B O M
Production BOM
Document Structure
Engineering BOM
Change No.
Plant A
Release to Plants
CAE (Chrous, IDEAS)
Fix Parts
Plant B
(Group BOM)
Change History
D M S
WBS
CAD/CAM

• General Ledger
• Cost Center

Create Original
Doc. Info Records
Posting
R/3 4.0
(Time/Money/Document)
VAULT
Web Browser
Texts
Drawings
Images
Web Server
36
DFSS ??? ??
DFSS ???? ?? ?? Dash Board ???? ?? ??? ??
37
Benefits of DFSS
????
38
????
DFSS? ??? ?? ??
? DFSS ?? ???? ??
CTQ? ??
VOC? ?? ??
r1 ?
r2 ?
t ?
?????
Yf(x)
Design ???? Zst6.0
Zlt4.5
? ?? ?? ? ?? ??
Mfg? ?? ?? ??
VOC? ??? ?
Yf(x)
CTQ? ?
Admin? ???? ?? ??
? ?????? ???? ??
39
?? SDI DFSS IntraNet Navigator