Design for Six Sigma (DFSS)

Course Summary

Design for Six Sigma (DFSS) training equips designers in NPD, NPI, or R&D with essential tools and advanced strategies to navigate customer requirements, optimize designs, and follow the Six Sigma Define, Measure, Analyze, Design, and Verify (DMADV) process for successful product development.

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Event Details

88 hours
Instructor-led class training, with opportunities to practice learned skills using prepared data, live demonstrations, and data collected real time in class
Minitab or JMP Statistical Software

Description

Designers for NPD, NPI or R&D face challenges to understand the customer requirements, relate customer requirements to product requirements, select a design approach, evaluate design choices, optimize a design and verify the design in manufacturing. This training addresses these fundamental needs of designers and is organized around the five main phases of the Six Sigma Process Improvement Roadmap: Define, Measure, Analyze, Design, and Verify (DMADV).

The first half of the program can be run independently and gives participants essential tools for the Define, Measure, Analyze, and Design functions. The second half provides tools and advanced strategies to complete the Design and Verify steps of the roadmap.

Optional: In between training, QSG provides coaching and guidance to ensure that the methodology and roadmap are used appropriately. This is a separate service provided apart from this 80-hour training program.

Who Should Attend

This course is designed for R&D and design engineers and leaders who will head or work on new product development or new product introduction activities.

Learning Objectives

Through training, participants will:

  • Know the roadmap DMADV to systematically define, measure, analyze, design and verify
  • Know how to identify projects and define the project charter
  • Achieve an in-depth understanding of the knowledge-based and data-based (statistical) methods to improve the design process
  • Be able to design experiments to characterize and optimize a design with respect to controllable process factors
  • Know various methods to verify design performance in manufacturing

Course Outline

PhaseChapterTopics
Phase 1 (48 hrs)

Define/Measure/Analyze

  • Introduction to Design for Six Sigma
Why use DFSS and Goals of DFSS DFSS Roadmap: DMADV

Project Scoping and Chartering

  • QFD: Quality Function Deployment
Where QFD is used

VOC: Voice of the Customer

Kano, KJ Analyses and House of Quality

  • Essential Statistical and Quality Tools
Introduction to Minitab or JMP Common vs. Special Cause Measuring Center, Spread and Shape
  • Control Charts
Xbar/R, I/MR, Attribute Charts
  • Measurement System Analysis
Resolution, P/T, P/V and ndc Metrics Planning, Executing and Analyzing a GRR Attribute GRR
  • Capability Analysis
Capability Indices Cp, Cpk, Ppk and SCpk Capability Graph
  • Critical Parameter Management
Critical Parameter Management Scorecard
  • Design FMEA
Types of FMEA’s: DFMEA and PFMEA How to Perform a DFMEA
  • Statistical Tolerancing
Methods of Tolerancing Simulation Method
  • Statistical Reasoning
Real vs. Noise Decisions

4 Steps in a Test and 2 Decision Errors

5 Conditions to Accept a Conclusion

  • One-Two and Three or More Sample Comparisons
Comparison of Alternatives: t-Tests and ANOVA
  • Regression Analysis
Modeling Continuous Relationships 
  • Chi-Square Analysis
Modeling Discrete Relationships
  • Design Selection
Pugh Concept Selection
  • Design of Experiments
DOE for Characterizing: 1 Factor Designs and General Full Factorial Designs
Phase 2 (40 hrs)

Analyze/Improve/Control

  • Advanced DOE
Screening Designs: Fractional Factorial Designs

Characterizing: 2k Factorial Designs Design Strategies for Optimization Optimization of Multiple Responses Simultaneously

  • Design for Manufacturability
Robust Design and Ruggedness Testing
  • Manufacturing Implementation
Setting Process Specifications Non-Normal Control Charts
  • Design Verification
Qualification, Verification and Validation Equivalence Tests

Sequential Testing

  • Product and Process Reliability
Reliability Concepts

Reliability Growth Programs Demonstration Tests

Accelerated Testing

 

Prerequisites

None

Instructors

Paul Mullenix, Ph.D.

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