Lean Six Sigma Green Belt Certification Course

Design for Six Sigma (DFSS)

Methodologies
 WHAT’S IN IT FOR ME

Roadmap for Design

for Six Sigma (DFSS)

DFSS Tools
 Course Curriculum

Concept for design of six sigma

Impact of DFSS on an organization
DFSS and DMAIC methodologies
Types of DFSS Methodologies
 INTRODUCTION

60 days 5%

? What improvement methodology can be used?

 INTRODUCTION

60 days 5%

! Design For Six Sigma Methodologies (DFSS)

 CONCEPT OF DESIGN FOR SIX SIGMA
(DFSS) MEANING OF DFSS

QFD
FMEA
 IMPACT OF DFSS ON AN ORGANIZATION
BENEFITS OF DFSS

Entirely new product, Customer Completely improves existing

service, or process requirements product, service, or process

Add to existing product, service, or

process
 TYPES OF DFSS METHODOLOGIES
DMADV AND IDOV

Methodologies

Define
Identify

Verif Measure
y Design
DMADV Validate IDOV

Optimize
Design Analyze

For existing For new

products/services products/services
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF DMADV

Customer
requirements
Define
Goals for the
process,
product, and
Verif Measure service
y DMADV

Design Analyze
Define customer requirements and goals for the process,
product, and service.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF DMADV

Define
Performance

Verif Measure
y DMADV
Customer satisfaction

Design Analyze
The performance is measured and matched to the
customer requirements or benchmark.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF DMADV

Define

Verif Measure
y DMADV

Design Analyze
Design options are analyzed and assessed for the
process, product, or service to meet customer needs.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF DMADV

Define

Verif Measure
y DMADV

Design Analyze

Design and implementation of new processes

 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF DMADV

Define
Performance

Verif Measure
y DMADV

Design Analyze
Results that meet customer needs are verified to
maintain performance.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF IDOV

Identify

Design
Validate IDOV

Optimize

Customer needs and specifications are identified to

design the product or service.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF IDOV

Identify

Design
Validate IDOV

Optimize
Design alternative solution concepts by identifying
functional requirements, select the best fit, and predict
Sigma capabilities.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF IDOV

Identify

Design
Validate IDOV

Optimize

Optimize by calculating tolerance using statistical tools

and modeling to predict performance.
 TYPES OF DFSS METHODOLOGIES
EXPLANATION OF IDOV

1 2 Identify

3 Design
Validate IDOV

Optimize

Verify the design by testing, validating, and checking

conformance to Six Sigma Standards.
 DFSS AND DMAIC
SIMILARITIES AND DIFFERENCES

Similarities Differences

DMAIC
Tool improves
s an existing
Six Sigma process DMAIC
levels of focuses on
performance one or two
customer
requirements

Six Sigma
Benchmarking
philosophy is crucial for
DFSS DMAIC DFSS projects
Knowledge Check
KNOWLEDGE
CHECK
Which of the following is NOT a focus area for DFSS?

a. New processes

b. Fixing one element of existing process

c. New products or service

d. Adding to an existing product line

KNOWLEDGE
CHECK
Which of the following is NOT a focus area for DFSS?

a. New processes

b. Fixing one element of existing process

c. New products or service

d. Adding to an existing product line

The correct answer is. b.

Explanation: DFSS is focused on completely overhauling the process and not just one element.
KNOWLEDGE
CHECK
Which of the following is NOT a DFSS methodology?

a. IDOV

b. DMAIC

c. DMADV

d. Identify, Define, Optimize, and Verify

KNOWLEDGE
CHECK
Which of the following is NOT a DFSS methodology?

a. IDOV

b. DMAIC

c. DMADV

d. Identify, Define, Optimize, and Verify

The correct answer is. b.

Explanation: DMAIC is not a DFSS methodology.
 DFSS TOOLS
QFD AND FMEA

QFD
FMEA

DFSS
QUALITY FUNCTION DEPLOYMENT
(QFD) DFSS TOOL

Listen to
customers’
needs

Set
Respond to
development
the needs
targets

Customer's’ needs or
voice of the
customer
Define
Prioritize
requirements
 QFD HOUSE OF QUALITY (HOQ)
STRUCTURE
RELATIONSHIP BET WEEN THE STRUCTURES

Roof

Technical requirements

Customer Interrelationships matrix Planning matrix

requirements
Customer
requirements

Target
s
 QFD HOUSE OF QUALITY (HOQ)
STRUCTURE
RELATIONSHIP BET WEEN THE STRUCTURES

Roof
Correlates
organizational
characteristics

Technical
requirements
Lists characteristics
Customer Interrelationships matrix
influenced
Planning matrix
requirements

Lists customers’ Identifies the impact of Compares our

needs organizational characteristics performance
on customers’ requirements

Targets
Identifies targets
 FAILURE MODES AND EFFECTS ANALYSIS (FMEA)
DFSS
TOOL

DFSS FMEA DMAIC

Identifies Prioritizes
Identifies
consequences failure to see
possible failures
of failure critical
areas
 FMEA RISK PRIORITY NUMBER (RPN)
TOOL TO ASSESS RISKS

FMEA Risk Priority Number (RPN) = Severity * Occurrence * Detection

1 10
Severity None Hazardous

1 10
Occurrence Remote Very high frequency

1 10
Detection Very detectable Extremely undetectable
 RPN AND SCALE CRITERIA--SEVERITY
SEVERIT Y
RATING

Effect Severity of Effect Rating

Hazardous without Very high severity ranking when a potential failure mode affects safe 10
warning system operation without warning
Hazardous with Very high severity ranking when a potential failure mode affects safe 9
warning system operation with warning
Very high System inoperable with destructive failure without compromising 8
safety
High System inoperable with equipment damage 7
Moderate System inoperable with minor damage 6
Low System inoperable without damage 5
Very low System operable with significant degradation of performance 4
Minor System operable with some degradation of performance 3
Very minor System operable with minimal interference 2
None No effect 1
 RPN AND SCALE CRITERIA--OCCURENCE
OCCURENCE RATING

Effect Failure Probability Rating

Very High: Failure is almost inevitable due >1 in 2 10
to this cause 1 in 3 9
1 in 8 8
High: Repeated failures due to this cause
1 in 20 7

1 in 80 6
Moderate: Occasional failures due to this
1 in 400 5
cause
1 in 2,000 4

Low: Relatively few failures due to this 1 in 15,000 3

cause 1 in 150,000 2
Remote: Failure is unlikely due to this <1 in 1,500,000 1
cause
 RPN AND SCALE CRITERIA —
DETECTION DETECTION
RATING
Detection Likelihood of detection by Design or Process Control Ranking

Absolute Design/process control cannot detect potential cause/mechanism and subsequent failure mode 10
uncertainty
Very remote Very remote chance the design/process control will detect potential cause/mechanism and subsequent failure 9
mode
Remote Remote chance the design/process control will detect potential cause/mechanism and subsequent failure mode 8

Very low Very low chance the design/process control will detect potential cause/mechanism and subsequent failure mode 7

Low Low chance the design/process control will detect potential cause/mechanism and subsequent failure mode 6

Moderate Moderate chance the design/process control will detect potential cause/mechanism and subsequent failure mode 5

Moderately high Moderately high chance the design/process control will detect potential cause/mechanism and subsequent failure 4
mode
High High chance the design/process control will detect potential cause/mechanism and subsequent failure mode 3

Very high Very high chance the design/process control will detect potential cause/mechanism and subsequent failure mode 2

Almost certain Design/process control will detect potential cause/mechanism and subsequent failure mode 1
 FMEA TABLE
USING THE FMEA TABLE TO PLAN IMPROVEMENT INITIATIVES

How and
Prevention of
why failures
failures
happen

Key Potential Potential

Process Potential
Process Failure Failure SEV OCC Current Controls DET RPN
Step Causes
Input Mode Effects

What is What is In what What is the How What How often does What are the existing How well SOD
the the key ways impact on the severe is causes cause or controls and can you
process does the key output the effect the Failure Mode procedures detect
step? process key variables to the key (FM) occur? (inspection and test) cause or
input? input go (customer customer? input to that prevent the cause FM?
wrong? requirements) go or the FM? Should
or internal wrong? include an SOP
requirements? number.
 TYPES OF FMEA
PFMEA AND DFMEA
Process Failure Mode Effects Analysis Design Failure Mode Effects Analysis
(PFMEA) (DFMEA)

Used on new or Used in the design

existing processes of a new product to
to uncover potential uncover potential
failures failures

Done in the quality Aimed at identifying

planning phase to failure modes
act as an aid during effects and reducing
production them
Involves
fabrication, Done before
assembly, product is sent to
transactions, or manufacturing
services
All significant
design deficiencies
are resolved at the
end of this process
APPLYING FMEA IN A SITUATION
PRIORITIZING RISKS USING DFMEA

RISK
 APPLYING FMEA IN A SITUATION
PRIORITIZING RISKS USING DFMEA

FMEA Table

Process/ Sev Occ Det New Sev.

Responsi
Potential Potential Potential Current Recomme bility &
Action New Occ New Det New RPN
Product Failure Effect(s) cause(s) of Design RPN nded Target
Taken (On) (Dn) (RPNn)
Characte Mode(s) of (S) failure (O) (D) Action(s) Completi (Sn)
r istics failure Control on Date

Increase
Non- Set the set
Minimum
availability minimum limit for Managem
7 2 126 limit 4 1 36
of cash in limit regularly ent
increased
the ATM warning or often
Customer used ATM
Cash
account Extremely
withdraw
debited unhappy 9 9
al from
but cash customer
ATM
not paid

Increased
Technical
Increase the limit
Network and
5 None 9 405 and have 2 3 54
issue Managem
network load
ent
limit balancing
 TIPS AND TRICKS

Start the FMEA

Plan the FMEA analysis as soon as
carefully. possible.

You need knowledge of You need knowledge of You need knowledge of

systems operations to DFMEA before drawings PFMEA before production
complete an FMEA. are complete. plans are final.
 KEY TAKEAWAYS

DFSS is an approach that ensures a new

product or service meets customer
requirements.
DMADV and IDOV are two types of DFSS
methodologies.
It is a process at the Six Sigma level that
uses tools such as QFD and FMEA.
QFD is a focused methodology for carefully
listening to the customers’ needs or voice of
the customer.
FMEA is an approach to identify all possible
failures in a design, process, product, or
service.
There are two types of FMEA—PFMEA and
DFMEA.
The FMEA RPN is a measure used to
quantify or assess risk associated with a
design, process, product, or service.
Quiz
QUIZ
Which of the following is NOT true of DFSS?
1

a. It has focuses on quality.

b. Its purpose is to design a new process that meets customer needs.

c. It fits under the Six Sigma umbrella.

d. It targets only one customer requirement.

 QUIZ
Which of the following is NOT true of DFSS?
1

a. It has focuses on quality.

b. Its purpose is to design a new process that meets customer needs.

c. It fits under the Six Sigma umbrella.

d. It targets only one customer requirement.

The correct answer is.d.

Explanation: Design for Six Sigma, DFSS, ensures that all customer requirements are
achieved.
QUIZ
What is the expansion of FMEA?
2

a. Failure Modules and Effects Analysis

b. Failure Modes and Effects Analysis

c. Failure Median and Effects Analysis

d. Failure Modes and Effort Analysis

 QUIZ
What is the expansion of FMEA?
2

a. Failure Modules and Effects Analysis

b. Failure Modes and Effects Analysis

c. Failure Median and Effects Analysis

d. Failure Modes and Effort Analysis

The correct answer is b. .

Explanation: FMEA stands for Failure Modes and Effects Analysis.
QUIZ
Which of the following is NOT a section in a QFD’s HOQ matrix?
3

a. Customer Requirements

b. Roof

c. Basement

d. Planning Matrix
 QUIZ
Which of the following is NOT a section in a QFD’s HOQ matrix?
3

a. Customer Requirements

b. Roof

c. Basement

d. Planning Matrix

The correct answer isc. .

Explanation: The six sections of a House of Quality (HOQ) matrix are customer
requirements, planning matrix, technical requirements, interrelationship matrix, roof, and
targets.
This concludes Design for Six Sigma (DFSS)
Methodologies.
The next lesson is “Project Identification.”
THANK
YOU