DIDIN - Design For Six Sigma - 3

DFSS in New Product Development
Case Study of the Securekey Project

by Ray Balisnomo
April 21, 2010: Version 6

This DFSS Approach is NOT Practical
Project goals
Define Customer analysis
Create team
Capture voice of the customer
Measure Determine project schedule
Review risk assessment
Develop CTQs
Analyze Determine project schedule
 Review risk assessment
Develop models
Design Review CTQs
Review CTQs
Optimize Test tolerances
Optimize design
Compare product to initial specs

Verify Document development
2 Synopsis of DFSS Method

DFSS in Practice at Ingersoll Rand
Quality Function DFSS Design

Predict
We use the other DFSS Tools

Deployment (QFD) Scorecard
(e.g., DOE, Regression, Pugh
matrix, ANOVA, etc.) to close Customer
Customer Needs the gap between what the Satisfaction
customer desires & how the
actual product performs..
System
System Design
Capability
Subsystem Subsystem
Design Capability
Validate
Component Component
Design Capability
Process Process
Design Capability
Critical to Quality (CTQ) Management

Kano Analysis
Basic Needs (e.g., Test Requirements)
Customer Marketing
surveys or Requirements
interviews Document Performance needs
(Focus Groups)
Excitement needs or Delighters
Product
Specifications
AHP Pair-wise
Comparison
New SecureKey
Tradeoffs
Syn e rg y 1 .0
C ompr o mis e - 1.0
C on c ep t Se le ctio n
Bette r 1 .0
Same 0 .0
Wo r s e - 1.0
Prioritized or Weighted
I m p or t a nc e o f th e W HA T s ( A H P )
K e y in se r t ion & e xt r a ct io n f or c e
Nu m b e r o f r e ke y s t o f a ilur e
I m pr o ve m en t F a ct o r
O u r C ur r e nt P r o d uc t
O ur Cu r r en t P r od u ct
T im e t o r e ke y c y lin d er
Direction of Improvement
Customer Needs
Nu m b e r o f lif e c y cle s
K e y o p er a tin g t o r qu e
P e r ce n t I m po r ta n ce
Ov e ra ll Im p or t an c e
P lu g p ull s tr e n gt h
Max imiz e 1 .0
Tar g et 0 .0
K w ik S e t
K wik S e t
Min imiz e - 1.0
(WHAT’s)
R ie ld a
M a x = 1 .0
M in = - 1 .0
R ie ld a
B e st
B es t
1
Dir e ctio n of Imp r o ve me n t 1
Eas y to R ek e y 1 51 1 .2 6 1.2 5 2.6 1
Hig h ly Sec u r e 2 35 1 .2 4 2.0 3 6.1 2
Op e ra te s Smoo thly 3 10 1 .0 1 0.0 8 .6 3
Re k ey a ble Mu ltiple Time s 4 4 0 .8 3 .2 2 .7 4
Quality Function System-level CTQ’s.

3 2. 4 4 99 . 0
2 1. 8 3 36 . 1
1 5. 5 2 37 . 8
1 4. 2 2 18 . 6
1 2. 6 1 93 . 8
Imp o rta n ce o f th e HO Ws 1
5 2. 9
Standard 9-3-1
Per c en t Imp o rta n ce o f th e H O Ws 2
3 .4
Stro n g 9 .0
Deployment HOW do we measure

Max = 3 2 .4 Mod e ra te 3 .0
Per c en t Imp o r ta n ce o f th e HO Ws We a k 1 .0
Min = 3.4
Kwik s et 4
R ield a
Be st L oc k s
5
6
(HOQ-1) success?
Ta rg e ts fo r O u r Fu tur e Pr o du c t 7
1

Quality Function
Predict
Deployment (QFD)
Customer Needs
System Design

Tradeoffs
System Level Q.F.D. Syn e rg y

C ompr o mis e
1 .0
- 1.0
K e y I n s er t ion & E xt r ac t ion F o r c e

I m p or t a nc e t o th e C u st o m e r
Nu m b e r o f Cy ce ls t ill F a ilur e
P er c ep t ion s o f K w iks e t
P er c ep t ion s o f Rie lda
P er c ep t ion s o f B e s t
T im e t o r e ke y cy lind e r
K e y O p er a t in g F o r ce
P lu g p u ll s t re n gt h
Max imiz e 1 .0
Tar g et 0 .0
Min imiz e - 1.0
M a x = 5 .0
M in = 0 . 0
1
5
Dir e ctio n o f Imp r ov e me n t 1
1
Eas y to Re k ey 1 42
2
Hig h ly Sec u r e 2 38
3
Op e r ate s Smoo thly 3 12
4
Re k ey a ble Mu ltiple Time s 4 8
4 14
3 54
2 00
1 50
1 14
Imp o rta n ce o f Pr od u ct Attrib u tes 1
Max = 4 1 4.0
Standard 9-3-1
Imp o r ta n ce o f Pr o du c t Attr ib u tes
Stro n g 9 .0
Min = 11 4 .0 Mod e ra te 3 .0
4 80 K We a k 1 .0
2 36 6 3 80 0
Bes t Pe r for man c e 3

1 25
3 .8
3 .2
Kwik se t Pe r for man c e 4

5 00 K 3 20 K 2 2K
4 .2
2 .3
55
2 74 5
Rie ld a Per fo r ma nc e 5
5 .2
3 .5
30
3 80 0
Tar g et Valu e s 6
3 .5
2 .0
30
1

Pugh Matrix for Concept Selection

Quality Function
Predict
Deployment (QFD)
Customer Needs
System Design
Subsystem
Design

Sub-system
Clearance btwn Tongue Pin and R Sidebar
Clearance btwn Tongue Pin and Key

Level Q.F.D.
Rack Pin Clearance with Plug Slot

End Play btwn Housing and Plug
Importance of Product Attributes

Kwikset Performance
Rielda Performance
Best Performance
Di re cti on of Im pro ve me nt
Target Values
Max = 414.0
Maximize 1.0
Min = 114.0
Target 0.0
Minimize -1.0
6
Direction of Improvement 1
Time to rekey cylinder 1 414 125 55 30 30 1
Plug pull strength 2 354 3800 2366 2745 3800 2
Key Insertion & Extraction Force 3 200 3.8 4.2 5.2 3.5 3
Key Operating Force 4 150 3.2 2.3 3.5 2.0 4
Number of Cycels till Failure 5 114 480K 22K 320K 500K 5

5352
3968
3726
3680
Importance of the Part Attributes 1 Sta nd ard 9-3-1
Max = 5352.0 Strong 9.0

Importance of the Part Attributes Moderate 3.0
Weak 1.0
Min = 3680.0
0.0060 in
0.0035 in
0.0185 in
Target Values 3
0.005 in
1

Quality Function
Predict
Deployment (QFD)
Customer Needs
System Design
Subsystem
Design
Component
Design

Surface Roughness of Recombinating Sidebar
Component
Level Q.F.D.
Rack Pin Counter-bore Diameter
Importance of the Part Attributes

Rack Pin Counter-bore Depth
DirectionofImprovement
Target Values
Max = 5352.0
Min = 3680.0
Maximize 1.0
Target 0.0
Minimize -1.0
3
Clearance btwn Tongue Pin and R Sidebar 1 5352 0.0060 in 1
End Play btwn Housing and Plug 2 3968 0.0035 in 2
Clearance btwn Tongue Pin and Key 3 3726 0.0185 in 3
Rack Pin Clearance with Plug Slot 4 3680 0.005 in 4

260.3
260.3
281.7
Importance of Process Attributes 1
Max = 281.7 Standard 9-3-1

Importance of Process Attributes
Strong 9.0
Min = 260.3 Moderate 3.0
Weak 1.0
Target Values 3
1

Quality Function
Predict
Deployment (QFD)
Customer Needs
o Design of Experiments
System Design
Subsystem
Design
Component
Design

Design of Experiments: Recombinating Sidebar Spring Retention

Component
Level Q.F.D.

Target Values
Max = 5352.0
Min = 3680.0
Maximize 1.0
Target 0.0
Minimize -1.0
3

260.3
260.3
281.7

Strong 9.0
Weak 1.0
Target Values 3 .028.069
1

Quality Function
Predict
Deployment (QFD)
Customer Needs
o Gauge R& R
System Design
Subsystem
Design
Component
Design

Measurement System Analysis: Surface Roughness(Ra) Lck.Sidebar

Quality Function
Predict
Deployment (QFD)
Customer Needs o Design of Experiments

o Gauge R& R
o Regression Analysis
System Design
Subsystem
Design
Component
Design

Binary Logistic Regression to Determine Upper Spec. Limit for
Surface Roughness for Locking Sidebar
30 27 Ra
e
P( failure) 30 27 Ra
1 e

Component
Level Q.F.D.

Target Values
Max = 5352.0
Min = 3680.0
Maximize 1.0
Target 0.0
Minimize -1.0
3

260.3
260.3
281.7

Strong 9.0
Weak 1.0
Target Values 3 .028.069 .92
1


Predict

o Gauge R& R
Customer Needs o Regression Analysis
System Design
Subsystem
Design
Validate
Component Component
Design Capability

Sub-system
Clearance btwn Tongue Pin and R Sidebar
Clearance btwn Tongue Pin and Key

Level Q.F.D.
Rack Pin Clearance with Plug Slot

End Play btwn Housing and Plug

Kwikset Performance
Rielda Performance
Best Performance
Di re cti on of Im pro ve me nt
Target Values
Max = 414.0
Maximize 1.0
Min = 114.0
Target 0.0
Minimize -1.0
6
Time to rekey cylinder 1 414 125 55 30 30 1
Plug pull strength 2 354 3800 2366 2745 3800 2
Key Insertion & Extraction Force 3 200 3.8 4.2 5.2 3.5 3
Key Operating Force 4 150 3.2 2.3 3.5 2.0 4
Number of Cycels till Failure 5 114 480K 22K 320K 500K 5

5352
3968
3726
3680
Importance of the Part Attributes 1 Sta nd ard 9-3-1
Max = 5352.0 Strong 9.0

Importance of the Part Attributes Moderate 3.0
Weak 1.0
Min = 3680.0
0.0060 in
0.0035 in
0.0185 in
Target Values 3
0.005 in
1

Tolerance Stack-ups using Monte Carlo Simulation


Predict

o Gauge R& R
System Design
Subsystem Subsystem
Design Capability
Validate
Component Component
Design Capability

Tradeoffs
System Level Q.F.D. Syn e rg y

C ompr o mis e
1 .0
- 1.0
K e y I n s er t ion & E xt r ac t ion F o r c e

I m p or t a nc e t o th e C u st o m e r
Nu m b e r o f Cy ce ls t ill F a ilur e
P er c ep t ion s o f K w iks e t
P er c ep t ion s o f Rie lda
P er c ep t ion s o f B e s t
T im e t o r e ke y cy lind e r
K e y O p er a t in g F o r ce
P lu g p u ll s t re n gt h
Max imiz e 1 .0
Tar g et 0 .0
Min imiz e - 1.0
M a x = 5 .0
M in = 0 . 0
1
5
Dir e ctio n o f Imp r ov e me n t 1
1
Eas y to Re k ey 1 42
2
Hig h ly Sec u r e 2 38
3
Op e r ate s Smoo thly 3 12
4
Re k ey a ble Mu ltiple Time s 4 8
4 14
3 54
2 00
1 50
1 14
Imp o rta n ce o f Pr od u ct Attrib u tes 1
Max = 4 1 4.0
Standard 9-3-1
Imp o r ta n ce o f Pr o du c t Attr ib u tes
Stro n g 9 .0
Min = 11 4 .0 Mod e ra te 3 .0
4 80 K We a k 1 .0
2 36 6 3 80 0
Bes t Pe r for man c e 3

1 25
3 .8
3 .2
Kwik se t Pe r for man c e 4

5 00 K 3 20 K 2 2K
4 .2
2 .3
55
2 74 5
Rie ld a Per fo r ma nc e 5
5 .2
3 .5
30
3 80 0
Tar g et Valu e s 6
3 .5
2 .0
30
1

Capability Studies: Plug Pull Strength


Predict

o Gauge R& R
System
System Design
Capability
Subsystem Subsystem
Design Capability
Validate
Component Component
Design Capability

Product Scorecard for Performance
Parts DPM Process DMP
System Level CTQ’s DPM
Time to Rekey Cylinder 538 0
Plug Pull Strength 0 631
Key Insertion & Extraction Force 838 425
Number Cycles till Failure Metric moved to the Reliability Scorecard
Sub-total 1376 1056
Total DPMO 2432

Equivalent Sigma or Z-score (short-term) 4.3

Predict

o Gauge R& R
o Regression Analysis Customer
Customer Needs
Satisfaction
System
System Design
Capability
Subsystem Subsystem
Design Capability
Validate
Component Component
Design Capability

Financial Benefit
• Securekey because it’s sold as part of a complete lock
generates $250Million per month, or $8.33 Million per day.
• As a stand-alone product, the key & cylinder generates at least
$70,000 a day in operating income or profit

Sajil Mathachan Kent Barker Scott Welsby Jason Clifford Brian Walls
Design Engineer & VAVE Engineer Leader of Design Design Engineer Design Engineer
Inventor Team

Team Members in Bangalore India (not pictured) : Ajeya Rao, Subashchandra Rai, and Jonah Pattar

DIDIN - Design For Six Sigma - 3

Uploaded by

Copyright:

Available Formats

DIDIN - Design For Six Sigma - 3

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DIDIN - Design For Six Sigma - 3

Uploaded by

Copyright:

Available Formats

DFSS in New Product Development

Case Study of the Securekey Project

April 21, 2010: Version 6

Compare product to initial specs

2 Synopsis of DFSS Method

Quality Function DFSS Design

We use the other DFSS Tools

Critical to Quality (CTQ) Management

3 Synopsis of DFSS Method

Basic Needs (e.g., Test Requirements)

Min imiz e - 1.0

Dir e ctio n of Imp r o ve me n t 1

Eas y to R ek e y 1 51 1 .2 6 1.2 5 2.6 1

Hig h ly Sec u r e 2 35 1 .2 4 2.0 3 6.1 2

Op e ra te s Smoo thly 3 10 1 .0 1 0.0 8 .6 3

Re k ey a ble Mu ltiple Time s 4 4 0 .8 3 .2 2 .7 4

Quality Function System-level CTQ’s.

Deployment HOW do we measure

4 Synopsis of DFSS Method

Critical to Quality (CTQ) Management

5 Synopsis of DFSS Method

System Level Q.F.D. Syn e rg y

K e y I n s er t ion & E xt r ac t ion F o r c e

Bes t Pe r for man c e 3

Kwik se t Pe r for man c e 4

6 Synopsis of DFSS Method

7 Synopsis of DFSS Method

Critical to Quality (CTQ) Management

8 Synopsis of DFSS Method

Clearance btwn Tongue Pin and R Sidebar

Clearance btwn Tongue Pin and Key

Rack Pin Clearance with Plug Slot

Importance of Product Attributes

Importance of Product Attributes

Time to rekey cylinder 1 414 125 55 30 30 1

Plug pull strength 2 354 3800 2366 2745 3800 2

Key Operating Force 4 150 3.2 2.3 3.5 2.0 4

Number of Cycels till Failure 5 114 480K 22K 320K 500K 5

Importance of the Part Attributes 1 Sta nd ard 9-3-1

Max = 5352.0 Strong 9.0

9 Synopsis of DFSS Method

Critical to Quality (CTQ) Management

10 Synopsis of DFSS Method

Rack Pin Counter-bore Diameter

Importance of the Part Attributes

Importance of the Part Attributes

Clearance btwn Tongue Pin and R Sidebar 1 5352 0.0060 in 1

End Play btwn Housing and Plug 2 3968 0.0035 in 2

Clearance btwn Tongue Pin and Key 3 3726 0.0185 in 3

Rack Pin Clearance with Plug Slot 4 3680 0.005 in 4

Importance of Process Attributes 1

Max = 281.7 Standard 9-3-1

11 Synopsis of DFSS Method

Critical to Quality (CTQ) Management

12 Synopsis of DFSS Method

13 Synopsis of DFSS Method

Rack Pin Counter-bore Diameter

Importance of the Part Attributes