DFSS - Design for Six Sigma

Introduction

ACTIVITY: Team introductions, team name selection and get to know each other activity. (20 min)

Course Objectives, Agenda Review

Understanding Six Sigma

What and Why Six Sigma
Six Sigma Overview
- Importance of Measurement
- Terminology, Definition of Six Sigma
- Six Sigma Strategies
- Six Sigma Roadmap

Six Sigma Design Overview

How is Design Different?
The DMADV Model
Selected Design Tools
Design Conditions
Design Scenarios

Define

Create the Vision
- Vision Ingredients
  
  ACTIVITY: Creating a vision. (20 min)
  
  ACTIVITY: Relations Diagram. (20 min)
  
  ACTIVITY: Change Readiness Assessment. (10 min)
- Assumption Busting
  
  ACTIVITY: Assumption Busting. (25 min)
Develop Design Strategy and Charter
- Multi-Generational Project Planning
  - Project phasing philosophies
- Business Case
- Opportunity Statement
- Goal Statement
  
  ACTIVITY: Critiquing opportunity and goal statements. (30 min)
- Constraints and Assumptions
- Scope
- Roles
- Preliminary Plan
  
  ACTIVITY: Create rough draft project charters, select team roles and responsibilities. (45 min)
- Building a Case for your Design Project
- Force Field Analysis
  
  ACTIVITY: Create an elevator speech. (25 min)
- Change Management/Stakeholder Analysis
  
  ACTIVITY: Perform a stakeholder analysis. (45 min)
- Building a Case for your design project
Gather Voice of the Customer Data
Effectiveness Assessment
- Understanding customer requirements
- Kano analysis
Sources of CTQs
- Customer research methods
  
  ACTIVITY: Discuss current VOC techniques. (20 min)
- Organizing VOC input
- Translating VOC into requirements
  - Affinity analysis, tree diagram. multivoting
    
    ACTIVITY: Analyzing customer needs.
Identify Initial Design Requirements
- Conjoint analysis
  
  ACTIVITY: Conjoint analysis. (20 min) [optional]
- Quality Function Deployment
  - House of Quality
  - Benefits
    
    ACTIVITY: QFD Rooms 1, 2, & 3. (20 min)
Clarify High-Level Process Structure
- SIPOC Diagram
- Design and process mapping
  
  ACTIVITY: Team discussion on best process map approach. (10 min)
  
  ACTIVITY: The pizza SIPOC. (10 min)
  
  ACTIVITY: List value-added, non-value-added and value-enabling activities from your knowledge of common business activities. (15 min)
Managing the Design Project
- Teamwork checklist: vital signs
- Components of good meetings
- Teamwork management roles
- Storyboards and tollgate reviews
Define Wrap-Up/Checklist Review

Measure

Measurement Concepts
Defining Measurement Objectives
- Design ("greenfield") vs. redesign
- Deciding what and where to measure
  
  ACTIVITY: How's your pizza process?
Prepare Definitions and Data Sources

ACTIVITY: Defining a measure. (10 min)
- Operational definitions
  
  ACTIVITY: Creating and testing operational definitions. (10 min)
- Data sources and data collectors
- Detailed process mapping
Create Initial Measurement Plan
- Sampling: methods, strategies, situations, biases
- Data types
- Constructing and using data collection forms
  - Types of checksheets and examples
- Preparing/training data collectors
Establishing Capability Baselines
- Process capability (Cpl, Cpu, Cpk)
- Defect measures (DPU, DPO, DPMO)
- Performance scorecards
Validate Design Benefits
- Cost of poor quality
- Financial impact assessment
- Benchmarks and best practices
Measure Wrap-up and Checklist Review

Analyze

Summary of Define and Measure
Analyze Challenges for Design/Redesign projects
Analyzing the Current Process
- Value and cycle time analysis
Assess Process Interfaces
- Interfaces & capability measures
- Defining spec limits
Balancing & Refining Requirements
- Performance vs. Satisfaction
- Revisiting the House of Quality (Room 2 and 8)
Challenging Design Assumptions
- Assumption Busting
- TRIZ: Inventive problem solving
  - Addressing design contradictions
    
    ACTIVITY: Analyze Planning.

Design

Generating Design Ideas
- Creating innovative ideas
- Planning for brainstorming sessions
- Brainstorming & advanced idea generation techniques
  
  ACTIVITY: Generating Ideas. (30 min)
- Narrowing Ideas & Developing Ideas
  - Mixing, matching and combining ideas
  - Solution filtering: Pugh matrix
Designing New Processes
- SIPOC (review)
- "Should Be" process mapping
- Workflow Design Opportunities
  - Organization Analysis
  - Deployment mapping
    
    ACTIVITY: Process Design. (90 min)
- Key Design Decisions: Criteria Matrix
Refining the Design
- "Talk-Through" and "Walk-Through"
  
  ACTIVITY: Talk-Through. (30 min)
- Risk Management
- Poke-Yoke: Mistake Proofing
  
  ACTIVITY: Risk Management. (45 min)
- Costing the Process
  
  ACTIVITY: Process Costing. (30 min)
Plan & Test the Design
- Process simulation and piloting
- Sampling situations: Population vs. Process
  - Biases, strategies
- Population Sampling Overview
  - Sample size calculations and worksheets
  - Sampling scenarios
- Population Sampling Overview
  - Sample size calculations and worksheets
  - Sampling scenarios
- Testing, Refining & Implementing Measurement
- Consistency & stability
- Design of Experiments (DOE)
  - Key terms, basic steps, assessing the results
    
    ACTIVITY: DOE opportunities. (20 min)
- Capability Flow Down & Flow Up
Validating & Implementing the Design
- Approvals & Buy-in
  
  ACTIVITY: Decisions and buy-in. (30 min)
- Design Theme
  
  ACTIVITY: Elevator Speech/Theme. (30 min)
- FMEA (Failure Modes and Effects Analysis)
  
  ACTIVITY: Identify two failure modes and note any possible changes to your design. (45 min)
- Organizational analysis and implementation planning
Design Summary and Checklist

Verify

Planning Ongoing Measurement
- SPC
- Dashboards
- Control Charts
  - Use and interpretation
  - Construction method
Developing Documentation
- What to document and why
- Revision planning for the process
  
  ACTIVITY: Documentation and control.
Process Management
- Process Owner Responsibilities
- Process Map
- Monitoring
- Response Plan
Verify Wrap-up and Checklist Review
Action Planning: Review, Conclusion and Next Steps

Six Sigma Design Course Outline

Six Sigma Design
Course Outline